Z9 Helicopter Maintenance Manual

Z9EH HELICOPTER
STANDARD PRACTICE
MANUAL
(Ⅰ)
ORIGINAL ISSUE: Jul. 15/2010
AVIC HARBIN AIRCRAFT INDUSTRY GROUP CO., LTD.

Harbin Aircraft Industry Group Co., Ltd
Z9 Helicopter Standard Practices Manual
GENERAL LIST OF EFFECTIVE PAGES
Chap-Sec-Sub No. Page No. Date

Inside Front Cover (I) 1 Jul. 15/2010
00-00-00-P1 1 Jul. 15/2010
00-00-00-P1 2 Jul. 15/2010
00-00-00-P2 1 Jul. 15/2010
Description 1 Jul. 15/2010
Record of Revisions 1 Jul. 15/2010
Record of Temporary Revisions 1 Jul. 15/2010
List of Service Bulletin 1 Jul. 15/2010
20-01-00-P5 1 Jul. 15/2010
20-01-00-P5 2 Jul. 15/2010
20-02-00-P5 1 Jul. 15/2010
20-02-00-P5 2 Jul. 15/2010
20-02-00-P5 3 Jul. 15/2010
20-02-00-P5 4 Jul. 15/2010
20-02-00-P5 5 Jul. 15/2010
20-02-00-P5 6 Jul. 15/2010
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20-03-00-P5 1 Jul. 15/2010
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20-03-00-P5 5 Jul. 15/2010
20-03-00-P5 6 Jul. 15/2010
Inside Front Cover (II) 1 Jul. 15/2010
20-04-00-P5 1 Jul. 15/2010
20-04-00-P5 2 Jul. 15/2010
20-04-00-P5 3 Jul. 15/2010
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Jul. 15/2010 Page 1
GENERAL LIST OF EFFECTIVE PAGES

20-06-00-P5 1 Jul. 15/2010
20-06-00-P5 2 Jul. 15/2010
20-06-00-P5 3 Jul. 15/2010
20-07-00-P5 1 Jul. 15/2010
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20-07-00-P5 3 Jul. 15/2010
20-08-00-P5 1 Jul. 15/2010
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20-09-00-P5 1 Jul. 15/2010
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SUMMARY
Chap-Sec-Sub No. DESCRIPTION

Inside Front Cover (I)
00-00-00-P1 GENERAL LIST OF EFFECTIVE PAGES
00-00-00-P2 SUMMARY
20-01-00-P6 CLEANING, PROTECTION TREATMENT AND
SPRAYING COATING
20-02-00-P6 GENERAL MAINTENANCE AND REPAIR
PROCEDURE
20-03-00-P6 REPAIR OF PARTS AND COMPONENTS
Inside Front Cover (II)
20-04-00-P6 CLEANING, PROTECTIVE TREATMENT AND
COATING
20-05-00-P6 SEALING
20-06-00-P6 BONDING
20-07-00-P6 OPERATIONAL SAFETY AND TECHNICAL
INSTRUCTIONS FOR GROUND TAXIING AND
INSPECTION AND LOADING TEST
20-08-00-P6 PERIODIC AND SELECTED MONITORING AND
INSPECTING PROCEDURES
20-09-00-P6 PARKING AND PRESERVATION
20-60-00-P6 ROTOR BLADES
00-00-00-P2
Jul. 15/2010 Page 1
DESCRIPTION
This manual is applicable to Z9 series helicopter, and the relevant issues are described as
follows:
1. The chapter-section-subjects and their contents are compiled according to Specification
ATA100 of the Air Transport Association of America.
2. The publication date (year-month-day) together with chapter-section-subject numbers and
pages numbers are marked at the lower left corner (even page) or the lower right corner
(odd page).
3. This manual will be supplemented and revised according to the production and operation
conditions of Z9 helicopter. In case the normal revisions are made to this Manual, the
Revision Pages, corresponding new List of Effective Pages and List of Revisions will be
issued to manual holders, and vertical black lines will be marked in left blanks
corresponding to revisions on the revised pages. The manual holders will replace the
pages according to the List of Revisions and the updated List of Effective Pages and
discard the pages replaced and temporary revisions, and make appropriate records on the
Record of Revisions. If temporary revisions are made to this Manual, incorporate a
Record of Temporary Revisions into front of the page to be revised and make appropriate
records on the pages of Record of Temporary Revisions, so as to ensure the completeness
and effectiveness of the data.
Description
Jul. 15/2010 Page 1
RECORD OF REVISIONS
Date of
Revision No. Date of Issue By Remarks
Incorporation
Record of Revisions
Jul. 15/2010 Page 1
RECORD OF TEMPORARY REVISIONS
Revised Section
Revision Date of Date of Reason of
Page By By
No. Chap-Sec-Sub Date Reception Cancellation Cancellation
No.
Record of Temporary Revisions

Jul. 15/2010 Page 1
LIST OF SERVICE BULLETINS
Service
Revision No. Date Incorporated by Description
Bulletin No.
List of Service Bulletins

Jul. 15/2010 Page 1
CHAP-SEC 20-01
LIST OF EFFECTIVE PAGES

20-01-00-P5 1 Jul. 15/2010
20-01-00-P5 2 Jul. 15/2010
20-01-00-P6 1 Jul. 15/2010
20-01-01-101 1 Jul. 15/2010
20-01-01-101 2 Jul. 15/2010
20-01-01-101 3 Jul. 15/2010
20-01-01-301 1 Jul. 15/2010
20-01-01-301 2 Jul. 15/2010
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20-01-01-302 1 Jul. 15/2010
20-01-01-302 2 Jul. 15/2010
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CHAP-SEC 20-01
20-01-01-304 2 Jul. 15/2010

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20-01-01-306 1 Jul. 15/2010
20-01-01-306 2 Jul. 15/2010
20-01-01-310 1 Jul. 15/2010
20-01-01-310 2 Jul. 15/2010
20-01-01-311 1 Jul. 15/2010
20-01-02-101 1 Jul. 15/2010
20-01-02-101 2 Jul. 15/2010
20-01-02-401 1 Jul. 15/2010
20-01-02-401 2 Jul. 15/2010
20-01-02-401 3 Jul. 15/2010
20-01-02-401 4 Jul. 15/2010
20-01-02-401 5 Jul. 15/2010
20-01-02-601 1 Jul. 15/2010
20-01-02-601 2 Jul. 15/2010
20-01-02-601 3 Jul. 15/2010
20-01-03-101 1 Jul. 15/2010
20-01-03-101 2 Jul. 15/2010
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CLEANING, PROTECTION TREATMENT AND SPRAYING COATING
TABLE OF CONTENTS
Chap-Sec-Sub No. Description
20-01-01-101 Various Kinds of Materials Used in Helicopter
20-01-01-301 Lubricating Grease
20-01-01-302 Lubricating Oil
20-01-01-303 Protection Materials
20-01-01-304 Special Material
20-01-01-305 Hydraulic Oil
20-01-01-306 Jet Fuel
20-01-01-310 Polysulfide Sealing Compound
20-01-01-311 Fluorocarbons sealing compound
20-01-02-101 Deionized Water
20-01-02-401 Use of Water
20-01-02-601 Analysis of Water
20-01-03-101 Selection of Aluminum Alloy
20-01-00-P6
Jul. 15/2010 Page 1
VARIOUS KINDS OF MATERIALS USED IN HELICOPTER
1 Lubricating Grease， Lubricating Oil， Special Material， Protection Material，

Hydraulic Oil and Liquid Fuel
1.1 General
This section provides List of Acceptable Material up to the design requirements. The
technical data of each kind of these materials is provided by supplier.
The following tables include from left to right：
— AIR Aeronautical Specifications.
— NATO Code.
— American and British Specifications.
— Technical data provided by supplier.
— Supplier.
— Product name of material.
— Qualification, at least in compliance with one national standard：
H— Authorized material.
A— Approved material.
**— Up to requirements of the specifications, but unapproved
— Country of production.
1.2 Class rating of material to be used
Table 20-01-01-301 Grease
Table 20-01-01-302 Lubricating Oil
Table 20-01-01-303 Protection Material
Table 20-01-01-304 Special Material
Table 20-01-01-305 Hydraulic Oil
Table 20-01-01-306 Jet Fuel
1.3 Definition of Specifications
France Specifications
AIR— Aviation Manufacture Technology Bureau.
DCEA— Army Petro Ctral Bureau.
NAM— Navy Department.
STM— Navy Advanced Technogical Security Bureau.
America Specifications
MIL— American Military Specifications.
20-01-01-101
Jul. 15/2010 Page 1
VV— American Federal Specifications.

TT— American Federal Specifications.
SS— American Federal Specifications.
OM— America Federal Specifications.
Britain Specifications
DTD— Department of Defense (Procurement Administration).
DEF— Department of Defense (Defense Material Standardization).
D.eng.D
D.eng.RD— Department of Defense (Procurement Administration).
DERO— General Engine Directorate.
DEF—STAN— Department of Defense (Standardization Directorate).
TS— Material Quality Assurance Directorate.
BS— British Standard Association.
2 Sealing Compound
2.1 General description
This section lists sulfide sealing compound (ThioKol) and fluoride sealing compound (Viton).
The following tables include from left to right：
— Aerospace.
— American or Aerospace (C.M) Specifications.
— Reference material of supplier.
2.1.1 Operation limits as per symbols：
Operation Environment and
Symbols Operation Environment and Limits Symbols
Limits
EG General sealing ED Removable parts
Sealing of fuel tank structure Removable doors and seals
Watertight seal ES Sealing massive area slow
Airtight—Repairing leakage curing
EE Encapsulation and coating of
electric connectors
EP Sealing plastics EF Internal processing of fuel
Windows and canopy made of acrylic tank
acid plastics
ER Sealing of fuel tank
Inserts —seal rubber strip-lap
joint-packing-filling and covering
2.1.2 Application mode as per symbols:
20-01-01-101
Jul. 15/2010 Page 2
Symbol Application Mode Number Signs Application Mode Number

EG Brush with high A EP Suitable spaying B
viscosity gun or scraper
Spaying gun or scraper B ES Brush
with high viscosity EF Brush with very low N
viscosity, through
ER Brush with high A dipping, filling and
viscosity draining
Spaying gun or scraper B
with high viscosity
ED Brush with low A EE Spaying gun or
viscosity scraper with high
Spaying gun or scraper B viscosity
with low viscosity
Numbers A, B and C are equal to the reference data of the class ratings of American
Specifications and suppliers
A- Certain liquid material is class A.
B- Certain semi-solid material is class B.
N- None.
2.2 Types of finished materials
Table 20-01-01-310 Polysulfide sealant
Table 20-01-01-311 Fluoride sealant
2.3 Preparation and application of finished materials
Refer to Chapter 20-05 in the Standard Practices Manual of Z9 Helicopter made by the
Harbin Aircraft Manufacturing Corporation (HAMC).
3 Use of Water
3.1 General description
This chapter specifies kinds of water used for rinsing after neutralizing treatment in
surface treatment tank.
3.2 Classification of water
A - Deionized water.
B - Tap water.
C – Water from other sources.
3.3 Inspection method
The inspection method is given in the Standard Practices Manual 20-01-01-601 of Z9
Helicopter made by the Harbin Aircraft Manufacturing Corporation.
20-01-01-101
Jul. 15/2010 Page 3
LUBRICATING GREASE
Specifications Technical Data

AIR NATO
Operation Drop
Aeronautical US UK Supplier Description (1) (2)
Temperature Point
Specs. Code
(℃) (℃)
-40℃ BURMAH CASTROL H
4205B G59 +77 > 260 FRANCE GREASE
USA
Inorganic AHT
grease -28 ELF ELF H
France
+150 210 FRANCE AVIATION
GREASE 05
-40 345 ESSO AVIATION H
France
204 GREASE 205
-40 240 KALOR KALOR H
France
+149 TRlTON
-40 210 NYCO GREASE H
France
+149 NYCO 50
-40 > SHELL AEROSHELL H

+177 260 GREASE 5
USA
-18 190 TOTAL TOTAL H
France
+170 (CER) AIR4205
4206B G355 MIL.C. DEF -40 Min. BURMAH CASTROL H

Graphite 21164 C STAN +120 150 FRANCE GREASE USA
inorganic or 91.54/
(MIL.C.
grease MIL.G. 1
8717
23549C
20-01-01-301
Jul. 15/2010 Page 1
AIR NATO
Aeronautic Operation Drop Supplier Description (1) (2)
al Specs. Code US UK
Temperature Point
(℃) (℃)
4206B -40 Min. BURMAH CASTROL H

graphite +180 150 FRANCE GREASE 7183
inorganic UK
grease
-40 150 ELF ELF H
+125 FRANCE AVIATION
GREASE 06 France
-40 185 KALOR GRAISSE H

+121 KALOR
ALTHEA France
G.R
-40 150 NYCO GRAISSE H
+121 NYCO 06
France
-40 Min. SHELL AEROSHELL H

+121 191 GREASE 8
UK
4207A G61 DTD -54 > 260 BURMAH CASTROL H

Lipid +177 FRANCE GREASE
extreme 5601 WTR
USA
pressure
grease
20-01-01-301
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AIR NATO
Aeronautic Operation Drop Supplier Description (1) (2)
al Specs. Code US UK
Temperature Point
(℃) (℃)
4207A
Acidic -55 280 ELF ELF H
extreme +175 FRANCE AVIATI0N
pressure GREASE 07 France
grease

+177 NYCO 07
France
-54 > SHELL AEROSHELL H

+204 260 GREASE 16
USA
4210B G54 MIL.G. DEF -73 188 BURMAH CASTROL H

Lipid 23827A STAN +135 FRANCE GREASE A
extreme Revision1 91. USA
pressure 53/1
grease
-73 > 170 ESSO 5114 EP H France

+150 GREASE USA
-73 181 KALOR KALOR H

+121 ANTARES
EP
France

+121 NYCO 10
France
20-01-01-301
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AIR
NATO
Operation Drop Supplier Description (1) (2)
Aeronautic UK
Code US Temperature Point
al Specs.
(℃) (℃)
-73 184 ORAPI LUBRI *
+121 MOLY M6 *
France
-73 184 RAFF GRAISSE H

+121 Imperator JET1036E
France
-73 260 SHELL AEROSHELL H

+149 GREASE 7
USA
4214B G363 MIL.G DEF 177 BURMAH CASTROL H

Fuel Revision 6032C STAN FRANCE GREASE PV
resistant 1 91.6/1
and Type 1
methanol USA
water
solution
grease
190 ELF AVIATION H
FRANCE GREASE 14
France

+121 NYCO HC
France
Min. SHELL AVIATION H

204 GREASE
USA
20-01-01-301
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AIR NAT
O
Aeronautic US UK
Temperature Point
al Specs. Code
(℃) (℃)
S7108
USA
4215B G382 MIL.G. DEF -40 > 260 BURMAH CASTROL H

inorganic 771A STAN +120 FRANCE (MIL.G.
grease Revision 91.12/ 7711A)
1(3) 1 GREASE France
-40 150 EIF ELF H

+121 FRANCE AVIATI0N
GREASE France
15

+125 GENERAL
PURPOSE
GREASE 1 France

+121
France
20-01-01-301
Jul. 15/2010 Page 5

AIR NATO
Aeronautical Operation Drop Supplier Description (1) (2)
Specs. Code US UK Temperature Point
(℃) (℃)
KALOR
ALTHEA
France
-40 > 260 NYCO GRAISSE H

+121 NYCO 15
France

+121 260 GREASE 6
USA
-40 190 O AL O AL H
+135 AIR
4215A
France
4217A G353 MIL.G. DEF -73 185 CAST CASTROL H

Molybdenum 21164 STAN GREASE
disulphide C 91. +135 ROL MSA
extreme 57/1 USA
pressure
grease

+121 KALOR
VITALIA
France

+121 NYCO 17
France
-73 220 ORAPI LUBRI **

France
20-01-01-301
Jul. 15/2010 Page 6

AIR
NATO
Aeronautical US UK
Code Temperature Point
Specs.
(℃) (℃)
+121 MOLY
M7 France
-73 185 RAFF IMPERATOR H

+121 Imperator JET 1520
France

+149 260 GREASE 17
USA
4222 G395 MIL. DEF -54 > 260 BURMAH CASTROL **

Synthetic G. STAN +177 FRANCE GREASE
hydrocarbon 81322 91 AU
grease C 52/1 USA
-54 316 ELF ELF H

+177 FRANCE AVLATION
GREASE 22
France
-54 > 260 ESSO AVIATION H

+177 GREASE
322
USA
-62 262 MOBIL MOBIL H USA

+177 GREASE 28
UK

France
20-01-01-301
Jul. 15/2010 Page 7

AIR
NATO
US UK Operation Drop
Supplier Description (1) (2)
Aeronautica Temperature Point
Code
l Specs. (℃) (℃)
+177 NYCO 22
France
-55 > 260 SHELL AEROSHELL H
GREASE 22
USA
4247A S720 MIL.T DEF 500 BURMAH CASTROL **

graphite 5544B STAN FRANCE B708
inorganic Revisio 80.
grease n1 80/1 USA
500 ELF ELF H

FRANCE AVIATION
GREASE
G.V. France
600 GRAPHOIL GRACO H

AG
50A France
500 KALOR KALOR H

HELENIUM
France
500 NYCO GRAISSE H

NYCO
GA47
UK
537 SHELL AEROSHELL H

UK
20-01-01-301
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AIR
NATO
Aeronautical US UK
Code Temperature Point
Specs.
(℃) (℃)
COMOP UK
UND 08
Note：
(1) Approved material：H.
Up to the requirements of specification，but unapproved material：※※.
(2) Country of production .
(3) Specification is invalid.
20-01-01-301
Jul. 15/2010 Page 9
Material Technical Data

Specifications Supplier Brand (2)
Nomenclature Drop Point
Fushun
Graphite
Q/SH006.1.59-92 149℃ Petroleum Plant
mineral grease
No.1
China
Fushun
Mineral grease QSH006.1.60-92 149℃ Petroleum Plant Z9-15
No.1
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LUBRICATING OIL

AIR NATO
Aeronautical Pour Flash Supplier Description (1) (2)
Specs. Code US UK Point Point
(℃) (℃)
Ester 0.156 MIL.L. -65 260 BURMAH CASTROL H
lubricating 23699 FRANCE 500
oil C
Revision USA
1
< -62.2 257 ELE CHEVRON H

FRANCE JET
ENGINE H
OIL5
USA
<-50 260 ESSO EXXON H

TURBO
OIL 2380
USA
-59 260 MOBIL MOBIL H

JET
OIL Ⅱ
USA
-58 254 MOBIL MOBIL H

JET
OIL 254
(RM254A) USA
-67 255 NYCO TURBONYCOIL H

525—2A
France
-63 260 SEHIL AEROSHELL H

TURBINE
OIL500 USA
20-01-01-302
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AIR
NATO
Pour Flash Supplier Description (1) (2)
Aeronautical
Code US UK Point Point
Specs.
(℃) (℃)
—62 260 CYCO TURBONY H
—COIL
599
USA
Note:
(1) Authorized material：H.
Approved material：A.
(3) If oil in the gear box is to be replaced, then the gear box should be cleaned according to
Aircraft Maintenance Manual。
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PROTECTION MATERIALS
Technical
Specifications
AIR NATO Data
US UK
Specs. Code Point Point
(℃) (℃)
1503B C.615 DEF -13 265 BP BPAERO H
Metallic STAN PRTOECIVE 5
UK
addition 91.
contained 40/1
protective oil -6.7 117 BURMAH CASTROLAERO H
for type A FRANCE STORAGE UK
piston engine OIL
-18 278 ELF AVIATION H
FRANCE PRESERVAIVE France
Type OIL100
France
BANOX624
-15 270 PCAS SKINOIL H
France
C615
-18 260 SHELL AEROSHEIL H
UK
FLUID 9
-13 268 SHELL AEROSHELL H
France
S.3323A
-15 270 TOTAL AEROPRO H
TECTIVE France
219
1503B C.609 MIL.C -15 260 BURMAH CASTROL **
Metallic 6529C 6529C
addition
free USA
protective oil
for type B
piston engine
20-01-01-303
Jul. 15/2010 Page 1
Technical
Specifications
Data
AIR
NATO
Code US UK
Specs. Point Point
(℃) (℃)
Replacement 2 FRANCE Type 2
TypeⅡ
USA
-18 270 ELF AVIATION H

PRESERVATIVE
FRANCE OIL 100
Type B France

BANOX
632 France
-23 233 MOBIL AUREX **

901
USA
-15 270 PCAS SKIN H

OIL C609 France
< -12 254 SHELL AEROSHELL **

FLUID2F
USA
1504B C.610 MIL.C. -48 150 BURMAH CASTROL **

Inorganic 6529C FRANCE 6529C
protective oil revision2 Type 3 USA
for turbine TypeⅢ
shaft engine
-45 148 ELF JE H

FRANCE PRESERVATIVE
OIL 15
France
-51 186 ESSO RUST H

BAN 633F France
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Technical
Specifications
Data
AIR
NATO
Code US UK
Specs. Point Point
(℃) (℃)
-50 170 PCAS SHELL A
C610 France
-44 148 SHELL SHELL **

STORAGE
OIL 3 USA
-44 148 SHELL SHELL H

S2466
France
1506A C.635 MIL.H. DTD < -60 100 BURMAH CASTROLAERO H

Hydraulic 6083D 5540B FRANCE 5540B
transmission Revision
UK
system mineral 3
protective oil
< -60 94 ESSO ESSO H

(3) INVAROL
FPJ13
France
-60 94 ESSO ESSO H

(4) INVAROL
France
PJ13
-59 100 MOBIL AVREX H

904 USA
< -60 98 NYCO HYDRAUNYCOIL H

FH6
France
< -60 96 PCAS SKINOIL H

C635
France
< -60 104 SHELL AEROSHELL H USA

(3) FLUID71
UK
20-01-01-303
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AIR
NATO
Code US UK
Specs. Point Point
(℃) (℃)
-60 104 SHELL AEROSHELL H USA
(4) FLUID7
UK
3634 C.634 DEF 53 ARDROX ARDROX H

Short term STAN 369/1
waterproof 6810/2 EL14 France
agent
45 BURMAH CASTROL H
FRANCE RUSTILO
DWX24 UK
< -30 40 CFPI PROLUB A

DEA 67
France
< -70 55 NYCO NYCOPROTEC A

344
France
< -70 45 ORAPI WR A

France
< -60 > 35 PCAS SKIN A

FILM
France
HLD 150
< -50 Min. SPCA PROTEX A

45 R09
France
38 ARDROX ARDROX H
3140 France
8132 C.620 MIL.C. 38 ARDR ARDROX

(P.2) 16173 OX 3140 France
Cold soft film D
protective oil Revision
2 +5 40 BURMAH CASTROL **
USA
20-01-01-303
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AIR
NATO
Code US UK
Specs. Point Point
(℃) (℃)
Class 2 FRANCE 16173D
Class 2
USA
ELF AVIATION **
FRANCE P2
France
PCAS PRODULE **
STOCKAG
—E8132
P2 France
45 SPCA PROTEX H
GM2
France
8136 C.627 MIL.C. 277 BURMAH CASTROL **

(P.6) 11796 FRANCE 11796B
Hot soft film D Cat. 3
USA
protective oil Type 3
ELF AVIVTION
FRANCE P.6
France
260 ESSO RUST H

BAN
326 USA
250 SPCA PROTEX H

GM6
France
Cold hard film C.632 MIL.L. BURMAH CASTROL **

protective oil 16173 FRAN- 16173D
D Class 1 USA
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AIR
NATO
Code US UK
Specs. Point Point
(℃) (℃)
Revision CE
USA
2
Class 1 63 CFPI ALA H
(P1) 77011 France
None ORAPI VERNIS **

SK05
France
45 SPCA PROTEX H
GM1
France
Hot hard film C.633 MIL.C. BURMAH CASTROL **

protective oil 11796 FRANCE 11796
C Cat. 1
Cat. 1 USA
71 280 ESSO RUST **

BAN 324 USA
250 SPCA PROTEX H

GM4
France
Hot hard film C.635 MIL.C BURMAH CASTROL **

protective oil 11796 FRANCE 117％
B Cat.1 USA
Cat. 1
250 SPCA PROTEX H

GM4 France
Semitransparent MIL.C. -25 41 ESSO RUST H RFA

cold soft film 16173 BAN 393
External D
protective oil Revision Min. SPCA PROTEX H
2 45 GM3
Class 3 France
Semitransparent MIL.C. -21 41 ESSO RUST H RFA

cold soft film
20-01-01-303
Jul. 15/2010 Page 6
AIR NATO Specs. Technical Data

Aeronautical US UK Point Point
Code
Specifications
(℃) (℃)
external 16173 BAN 397

protective oil D
Revision 2
Class 4 Min. SPCA PROTEX A France
P·9 45 1619
Note:
(1) Approved material: H.
Authorized material: A.
It is the material which is up to requirements of the specifications, but unapproved: **.
(2) Country of production
(3) Millipore filtered.
(4) Non-millipore filtered.
20-01-01-303
Jul. 15/2010 Page 7
SPECIAL MATERIAL
AIR
NATO
Code US UK
Specs. Point Point
(℃) (℃)
3565A S.743 VVP DEF 58 230 ELF AVIATION H
Mineral 236a STAN FRANCE VASELINE
Vaseline 9138/1
PX-7class France
56 268 ESSO AVIATION H

PETROLATUM
2
France
GRAPHOIL VASELINE H
3565
France
56 232 KALOR VASELINE H

ASCLERIA
France
63 230 NYCO VASELINE H

NYC065
France
Note:
(3) NATO Code is no longer valid.
20-01-01-304
Jul. 15/2010 Page 1

AIR
NATO
Aeronautical Flash Supplier Description (1) (2)
Code Pour Point
Specs. US UK Point
(℃)
(℃)
4223 S.740 MIL.M. DEF Powder＝95％ 1 DOW MOUKOTE **
Molybdenum 7866 2304 and≤40цm CORNING Z
disulphide C Operation
powder USA
temperature
is：
-200℃
+450℃ GRAPHOIL GRAPHOLL **
600 bis
France
KSPAUL KSPAUL **
POUDRE
N°3 UK
NYCO NYCO H
4223
France
ORAPI LUBRY **
MOLY
POUORE
PSM France
4224 S.732 SSG DEF GRAPHOIL GRAPH0IL **

Graphite 659a STAN 550
powder 96.1/1 France
Revision
2 NYCO NYCO H
4224
France
Note:
Up to requirements of Specifications，but unapproved material：**.
20-01-01-304
Jul. 15/2010 Page 2

AIR
NATO Pour Flash
Aeronautical Supplier Description (1) (2)
Code US UK Point Point
Specifications
(℃) (℃)
Dry-film S.749 MIL．L Operation DOW MOLYKTE H
lubricant 23398 temperature CORNING 3402 USA
B -198℃+135℃
Revision2 Operation ORAPI LUBRI A
temperature MOLY France
-200℃+430℃ SPAY
Operation ORAPI VIMOS A
temperature 70 France
-100℃ +150℃
Material Technical Data

Nomenclature Specifications Color Supplier Description (2)
Ice-control Liao Q167—87 Colorless,

chemical transparent, solid
impurity free
Dry-film lubricant Q/LM—101—91 Black grey Lanzhou Chemical HM101
Research Institute China
Dry-film lubricant Q/LM—102—91 Black grey Lanzhou Chemical HM102
Research Institute
Dry-film lubricant Q/LM—13—91 Green Lanzhou Chemical FM200
Research Institute
Note:
(1) Approved material: H.
Authorized material: A.
(3) The French Specifications corresponding to S749 is STPA№.34593.
(4) The Specifications are no longer effective.
20-01-01-304
Jul. 15/2010 Page 3
HYDRAULIC OIL
AIR
NATO
Code US UK
Specs. Point Point
(℃) (℃)
3520B H520 DEF <-60 96 BURMAH CASTROLAERO H
H520 grade STAN FRANCE HYDRAULIC
mineral 91.84/ 18
hydraulic oil 1
OM18 UK
Class
<-60 97 CAST— CASTROL **

ROL HYSPINA
USA
≤-63 97 ELF AVIATION H

FRAN— HYDRAULIC
CE OIL 20 France
<-60 97 ESSO AVIATION H

INVAROU 13
France
-59 93 MOBIL MOBIL A

AEROHFA
France
≤-66 89 NYCO HYDRAUNYC H

OIL FH5
France
<-60 99 PCAS SKINOIL H

H520
France
<-65 101 SHELL AEROSHEIL H RF
20-01-01-305
Jul. 15/2010 Page 1

AIR
NATO
Aeronautical US UK
Code Point Point
Specs.
(℃) (℃)
<-65 FLLUID 4
AEROSHELL
101 TOTAL FUID 520 H RF
3520B H515 MIL.H. DEF -62 90 BP BPAERO H

H515 grade 5606E STAN HYDRAULIC
Millipore 91.84/ 1B
filtered 1 UK
mineral DM15
hydraulic oil class
-62 110 BURMAH CASTR H

FRANCE OL AERO
585B
UK
≤-63 97 ELF AVIATION **

FRANCE HYDRAULIC
OIL 20B
H515
UK
<-60 97 ESSO AVIATION H

INVAROL
PJ13
France
-59 100 MOBIL MOBILAERO H

HFD
USA
20-01-01-305
Jul. 15/2010 Page 2
Technical
AIR Specifications
NATO Data
(1
Pour Flash Supplier Description (2)
Aeronautical US UK )
Code Point Point
Specifications
(℃) (℃)
≤-66 89 NYCO HYDRAUNYC H France
OIL FH51
<-60 99 PCAS SKYN OIL- H France

H515
<-65 93 SHELL AEROSHELL H RFA

FLUID41
Synthetic H537 MIL.H. -78 224 NYCO HYDRAUNYC H USA

hydrocarbon 83282 OIL FH2
hydraulic oil
Revision1 -62 218 SHELL AERO— H USA
Note:
(1) Approved material: A Authorized material: H.
It is the material which is up to requirements of the specifications, but unapproved: **.
(3) It will be described by France ELF.
(4) The SKYDROL50084 and LD4 are classified by ESSO and NYCO in France
20-01-01-305
Jul. 15/2010 Page 3
JET FUEL
Technical Data
Material Pour
Specifications Supplier Brand (2)
Nomenclature Color Point
(℃)
3# jet fuel GB6537—86 Clear and 38 Daqing Refinery RP—3
transparent Fushun Branch No.1
Note: (2) Country of production
NORMAL FUEL
Designation Code Specification Anti-icing Operation

(NATO) additive temperature
U.S U.K FRENCH Min. Max.
℃ ℃
JP8 kerosene F34 MIL-T D.Eng AIR Yes 50 - 50
50 -83133 RD 3405
(AVTUR-FS. JP8 2453 F34
Ⅱ)
JET A1 F35 ASTM-D-165 D Eng AIR No -20 50
kerosene 50 5 RD 3405
(AVTUR) JET A1 2494 F35
Kerosene — ASTM-D-165 — — No -20 50

5
JET A
High flash F43 — D.Eng AIR No -20 50
point RD 3404
kerosene 2498 F43
(AVCAT)
JP5
High flash F44 MIL-T-5624 D.Eng A2R3404 Yes -40 50
point JP5 RD F44
kerosene 2452
(AVCAT FS
Ⅱ) (JP5)
Kerosene Gost None
TS-1，RT 10227
20-01-01-306
Jul. 15/2010 Page 1
Harbin Aircraft Manufacturing Corporation (HAMC)
Z9EC Helicopter Standard Practices Manual
Substitution fuel
Designation Code Specification Anti-icing Operation

(NATO) additive temperature
U.S U.K FRENCH Min. Max.
℃ ℃
Wide cut F45 — D Eng — No -20 43
fuel RD
(AVTAG) 2486
JP4
Wide cut F40 MIL-T- D Eng AIR Yes -50 43
fuel 5624 RD 3407
(AVTAG FS JP4 2454
Ⅱ)
JP4
Fuels with operation limit
Designation Code Specification

(NATO) U.S U.K FRENCH
AVGAS F12 MIL-G-5572 － AIR3401

80/87 80/87
F18 MIL-G-5572 D.ENG.RD AIR3401
100/130 2485 100/130
F22 MIL-G-5572 D.ENG.RD AIR3401

115/145 2485 115/145
Automobile F46 MIL-G-3056 DEF.2401 DCEA/

gasoline 2DMT80
Tank gasoline
20-01-01-306
Jul. 15/2010 Page 2
POLYSILFIDE SEALING COMPOUND
Supplier and Code

Aerospace UK or US
Cat.
No. Specifications LE JOINT
PRO—SEAL 3M
FRANCAIS
EG-A1/2 RP1221A-1/2 PS707B5 EC1239A-1/2

EG-A2 MIL.S.7502C Pm221A-2 PS-EP-711
EG-A4 Class A Pm221A-4 EC1239A-2
EG-A8 Pm221A-8 EC1239A-4
EG-B1/2 MIL.S.7502C PR1221B-1/2 PS707 EC1239B-1/2

EG-B2 Class B PR1221B-2 PS-EP-711 EC1239B-2
EP-B2 MIL.S.7126A PR1222 EC612

Type Ⅰ
Polysulfide
ER-A1/2 MIL.S.8802E PR1422A-1/2 PS890A-2 EC1675-
ER-A2 Class A PR1422A-2 A-1/2

ER-A1/2 MIL.S.83430 PR1750A-1/2
ER-A2 Class A PR1750A-2
ER-B1/2 MIL.S.8802E PR1422B-1/2 PS890B-1/2 EC1675B-1/2
ER-B2 Class B PR1422B-2 PS890B-2
ER-B4 PR1422B-4 EC1675B-2
ER-B1/2 MIL.S.83 430 PR1750B-1/2
ER-B2 Class B PR1750B-2

ER-B4 PR1750B-4
ER-B6 PR1750B-6
ED-A1/2 MIL.S.87 84 B PR1321A-1/2
ED-A2 Class A PR1321A-2 PS706
ED-B1/2 MIL.S.87 84 B Pm321B-1/2

ED-B2 Class B Pm321B-2 PS706
ES LAC40 777 PR1431

Type 1 Type 1
EE MIL.S.85 16D PR11201 Q PS727 EC1641
Class 2
20-01-01-310
Jul. 15/2010 Page 1
POLYSILFIDE SEALING COMPOUND
Aerospace Chinese
Cat. Brand PRO-SEAL Supplier
No. Standard
Q/6S-952-91 HM101 No. 621 Institute, Beijing

Q/6S-957-91 HM102 No. 621 Institute, Beijing
Q/6S700-91 HM103 No. 621 Institute, Beijing
20-01-01-310
Jul. 15/2010 Page 2
FLUOROCARBONS SEALING COMPOUND
Supplier and Code

UK or USA
Type LE JOINT
Specifications PRO-SEAL 3M
FRANCAIS
Fluorocarbons Brush or spraying gun CM 024 PR1710
Washer CM 023 PR1720F
Large scope ladder track CM 022 PR1720SM
Tape CM 021 PR1720R
Filler CM 025 PR1720B
20-01-01-311
Jul. 15/2010 Page 1
DEIONIZED WATER
1 Deionized Water—Cat. A
The treated water should be up to following requirements of Specifications：
Resistivity ≥10Ωm
Water insolubles 0.0005g/L
Silicon (presented by sio) 0.0005g/L
≥7.0×10-2N/m
Surface tension
P P
PH 5～9
1.1 Operation standard of water：

Maintenance：the Repair and Overhaul Manual specifies the water types used for tank
solution and rinsing process used for surface treatment，and is deionized water is required.
The tap water can be used for all other treatment as long as requirements in Section 2 is met.
2 Inspection and Maintenance of Water Composition
2.1 Deionized water
2.1.1 Check of water：
Components of water to
Method (Task Card 20.0101601) Limits
be checked
Resistivity See 1.3 ≥103Ωm
P P
sio See 1.3 0.0005g/L
Water insolubles See 1.7 O.0005g/L
Surface tension See 1.1 ≥7.0×102N/m P P
When resistance coefficient is reduced to 10Ωm and below，the device must be upgraded.
2.1.2 Checking the water quality：
2.1.2.1 Direct water supply（see Para. 2.5.1）
Deionized water is directly flown into big tank via a plastic pipe line.
The resistance coefficient is continuously measured at the outlet of deionized water
pipe line.
2.1.2.2 Indirect water supply（see Para. 2.5.1）
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Jul. 15/2010 Page 1
Deionized water comes from storage water tank：

The resistance coefficient is measured at the outlet of
3 Tap Water— Cat. B：
3.1 Check：
Components of water to
Method (Task Card 20.0101601) Limits
be checked
Resistivity See 1.8
Ph See 1.8
Surface tension See 1.1 >7.0×10-2N/M

P P
Total hardness See 1.2
Water insolubles See 1.7 <2g/L
sin See 1.3
ci See 1.5
so See 1.4
3.2 Maintenance
Supply from tap water：
Periodically check the resistance coefficient ， whenever there is abnormal change in
resistance coefficient，it is necessary to comprehensively check all other components each
time..
Every time when the proximate content of water is greatly changed and it is possibly to have
affect on treatment，then you should request the quality assurance division of Harbin
Aircraft Manufacturing Corporation to examine the operation condition of deionized water.
Water from water sources
Maintenance is the same as that of city water source.
However, the water quality must be checked to make comparison with the quality of city
water supply, particularly, if there is suspended foreign matters in the water，then it is
necessary to filter the water
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USE OF WATER
1 Use of Cleaning Water

1.1 For different water use methods, see Fig. 1
(1) Indoor water consumption；
(2) Demineralized water consumption ；
(3) Circulating demineralized water；
(4) Prior to supply, demineralized water stored in container (method to prevent water
T T T T
from pollution)
Fig. 1
1.2 General rules of cleaning

There are two types of cleaning：
Intermediate cleaning to prevent one kind of tank solution from entering the following tank
solution：
Final cleaning, which is use to prevent polluted components from sediment on dry
operational parts，and to stop parts from being further treated.
1.2.1 Intermediate cleaning
With a part taken out of the treatment tank, according to the following conditions, the
part will trend to have residual liquid to some extent.
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Jul. 15/2010 Page 1
Their forms are as follows；

Their surface roughness;
The flow velocity of liquid.
In order to prevent one kind of tank solution component from entering the following
treatment tank, there must be a cleaning process between treatments.
However removal of pollution is thorough and is dependant on cleaning operation.
In accordance with concentration treatment tank solution, the connectors and
installation accessories on parts will be evaluated using following calculation values：
Volume of rinsing tank；
Discharging cycle of neutralization tank；
Flow of replaced water in flowing cleaning tank ；
Quantity of polluted element brought to the following treatment tank.
Lets take two treatment tanks 1 and 2 as example，their volumes are V1 and V2 B B B B
separately，and two tanks are separated by a cleaning drum R with volume V .
Fig. 2 Detail A
20-01-02-401
Jul. 15/2010 Page 2
Fig. 2 Detail B
For the convenience ， we consider that there is only element 1 with dissolved
concentration C in tank 1，and at the same time, and in tank 2，there is only element 2
with concentration C in tank 2.
Two types of rinsing are considered；
1) Rinsing in an indifferent tank (Fig.2 Detail A)
Rinse parts with a time interval △，and increase the concentration △C of one
element in immersion each time；
The concentration of 1 in the rinsing tank is increased to the maximum allowable
concentration in accordance with following assumptions，if this concentration is
exceeded；the tank solution must be replaced；
Polluted component concentration the instantaneous variation in the rinsing tank will
be the sum of the following items：
VdC=S P dt C1B B -S P dt C
Elimination of polluted component caused by residual matters
Pollutant retained on parts
Thus, following equation is obtained:
dc
V +SpC＝SpC
dt
The general expression for concentration element 1 in the rinsing tank is：
SP
C＝C [1-exp( t) ]
V
Where: t＝Operating time of rinsing tank
p＝Volume of attached tank solution 1 on one square meter area of a part.
20-01-02-401
Jul. 15/2010 Page 3
s＝Rinsed surface area.

Therefore, the formula can be roughly simplified into：
SP
C＝C-1 t
V
Therefore，when taking parts out of the rinsing tank，each rinsed part is attached with
a water volume p，and such kind of water contains element 1 with concentration C.
Concentration variation of element 1 in the rinsing tank solution is shown in Fig.2
Detail B.
2) Rinsing in a flowing tank solution (Fig.3 Detail A)
Fig. 3 Detail A
Fig. 3 Detail B
The rinsing tank solution shall be continuously replaced with clean water D( which
shall be equal to the volume of polluted and lost water).
Concentration variation of element 1 in the rinsing tank solution is shown in Fig.3
Detail B
rinsing tank element 1 concentration Concentration of element 1 in the rinsing tank is
given using following formula
20-01-02-401
Jul. 15/2010 Page 4
SP
C＝C1 D [1-f(t)]
B B
With “t” increased, the f (t) rapidly tends to zero.

When “t” is high enough, contaminant caused by retention on parts may be considered
that all is removed by replaced fresh water.
At this moment, the concentration expression of element 1 in No.1 tank will be:
SP
C = C1
D
- When a part is taken out of the rinsing tank, it has P liters of water/m2, and concentration P P
of water with element 1 contained is C.

After a time “t”, the element 1 is will be found in No.2 tank, of which the concentration
will be given by the following formula:
2 2
SP
C1 = C1 t
DV2
For example:
Tank 1: Sulfur- chromium acid of 300g/l H2SO4 B B B B
Flowing water rinsing tank: replacement water flow is 0.1 m3/h. P P
Tank 2: Chromium anodization

Surface area to be treated with fluid: V1=V2=20m3 B B B B P
Surface area to be treated per hour: S=8m2 P P
Hold-up: =0.2 l/m2 P P
The concentration of H2SO4 in the fluid of the rinsing tank: 5g/l.

B B B B
The concentration of H2SO4 in the fluid of chromium anodization tank: 5g/l.

B B B B
C1=3.8414t·g/I
P P
After 1300 hours of operation, sulfuric acid content will reach the limit (0.5g/l).
1.2.2 Final rinsing
The water used for final rinsing should be the water dripped from the fluid of tank, of
which the concentration of contaminated water should be lower than the extreme limits
specified in the specific document.
It can be obtained by any of following methods：
To increase the rate of liquid to be replaced in tank；
To carry out rinsing by using spray water.
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ANALYSIS OF WATER
1 General
1.1 Purpose
— In order to monitor the water quality used as surface treatment tank solution, the
T
detecting procedure of deionized water is specified as follows. T
1.2 Detecting items and monitoring standards are as follows：

— Surface tension ≥7×10-2N/m.
—Silicon (to be calculated as per sio2)<0.5mg/L.
B B
— Insolubles<5mg/L.
— Resistivity ≥107Ω.m (105Ω.Cm).
— PH 5~9
2 Detecting procedure
2.1 Calibration of surface tension
2.1.1 Instruments
— Interface tension meter
2.1.2 Procedure
— Carry out the detection as per the Instrument Instructions, record the surface tension
reading.
2.1.3 Results
Surface tension：Newton/meter (N/m).
2.2 Determination of silicon dioxide
2.2.1 Reagent
— Ammonium molybdate solution：2Sg/L.
— Perchloric acid solution：100g/L.
— 1 Amino-group -2 naphthol-4 sulphonic acid (A.N.S solid)
— A.N. solution：Resolve 10g neutral sodium sulfite in 200mL water，and then add
0.5g A.N.S，heat it until it is completely dissolved .
Note: A.N.S solution is very unstable, if it is frequently used, the preparation should be
made while using.
— Oxalic acid solution：100g/L.
— Silicon dioxide standard solution：It is called high quality pure sodium silicate
(Na2sios·9H20)4.73g，and it should be dissolved in water and diluted to 1L，stored
B B
in a plastic bottle，1mL of this solution ≈1mg of sio2. B B
2.2.2 Instruments
20-01-02-601
Jul. 15/2010 Page 1
— 721 type spectrophotometer.

2.2.3 Procedure
a. Standard curves
— Take standard solution (sio2 1mg/mL)10m1 respectively and put it in 1000mL
T T T T B B T T
volumetric flask，and use water to dilute to the graduation and shake it evenly.
T T
Concentration sio2 of this solution is 0.01mg/mL (hydraulic medium).

B B
— Take hydraulic liquid 0，5，10，20,30，40 mL and put them in 100Ml volumetric

flasks respectively，and add water to 50mL volume，then carry out as per “b” in
section 223.
— With mg number of sio2 as horizontal coordinate，and corresponding absorbance as
the longitudinal coordinate，draw a standard curve .
b. Sample determination
— Take 50mL(V) water sample and put it in 100mL volumetric flask.
— Add 5mL ammonium molybdate solution，20mL perchloric acid solution，3mL
oxalic acid solution，after stewing for 1 min，and add 5mL A.N.S solution.
—Add water to dilute it to the graduation，and shake it uniformly.
— After stewing for 15min，with reagent blank as blank solution，use 2cm color
comparator to measure the absorbance value under a waveform of 830nm .
2.2.4 Results
In accordance with absorbance, find out the sio quantity of corresponding to the
absorbance from the standard curve: calculate the contents of sio2 (m).
sio2 mg/L=m/V×1000
B B
2.3 Determination of insolubles

2.3.1 Instruments
— Infrared radiation heater.
— Borosilicate glass beaker：150mL.
2.3.2 Procedure
— Wash the beaker clean，heat it with constant temperature in the 110℃ bake oven for
half an hour，and then transfer it to a drier and weigh when it is cooled to the room
temperature, the value is P1 (g).
— Take 100mLwater sample (V) and fill it into a beaker.
— Carefully evaporate it in the infrared radiation heater till it is dried.
— After drying the beaker for 10min, heat it in the 110℃ bake oven for half an hour，
and then transfer it to a drier and weigh when it is cooled to the room temperature,
and repeat it in such a way until it is in a constant weight, the value is P2 (g).
2.3.3 Results
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Jul. 15/2010 Page 2
Insoluble mg/L= (P2-P1) ×1000×1000/V

B B B B
2.4 Measurement of resistivity

2.4.1 Instruments
— Conductivity meter.
2.4.2 Procedure
— With water sample put in a beaker，insert in the bright platinum electrode，carry out
the operation according to the steps required in the Instrument Instructions，and
record the conductivity readings (a).
2.4.3 Results
Resistivity (Ω·m)；106/a×100 P P
Note: water sample should not be exposed in the air for long time，measurement should
be done as quick as possible.
2.5 Measurement of PH
2.5.1 Instruments
— Take water sample of about 50mL (V) and put it in a beaker of 100mL，carry out the
operation according to the steps required in the Instrument Instructions. The general
operation steps are as follows：
• Turn on power and warm up for 30min，
• Use PH value standard solution (its PH value is more properly approximates the
solution under test) to position, correct and measure the PH value of water sample.
2.5.3 Precautions
— If there is crystallized Kcl in calomel electrode, then in operation, it is necessary to
remove the rubber cover on the bottom and rubber plug on the top, and recover after
using and put them into the box.
— Glass electrode should be placed in water after operation, and the liquid in the
electrode should be kept in contact with metal wire and unblocked.
— Don’t use glass electrode in oily or greasy solution, and after certain period of
operation, the glass electrode should be soaked in Hcl solution (1+20) for 2h, and it
can be reused after rinsing with water.
— The water sample must be analyzed as soon as possible and never open the cover
of water sample bottle before measurement.
— The temperature of PH value standard solution and water sample under
measurement must be the same as the room temperature.
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Jul. 15/2010 Page 3
SELECTION OF ALUMINUM ALLOY
1 General Description
Brands of aluminum alloy named with numbers in helicopter are prepared in accordance with
France standard NFA02.104 and America standard H.35.1.
The following is the numbers representation method of aluminum alloy brand which is
similar to American national standard specifications H.35.1.
2 Digital Representation：
— Both aluminum and aluminum alloy are named with 4 digits.
— Example of naming with numbers.
2 0 24
Example for alloy differentiating number
Original alloy
Copper element containing aluminum alloy
— Letter “A” preceded by numbers stands for French or European alloy, which can be used
in place of American alloy.
• For example：2618A(A-U2GN).
— Finished material with cover is named using alphabets preceded by numbers.
• For example：2618APL(A-V2GN/AZ1).
Brand up to Brand Previously Appearance of finished products

France/ Represented by
Alloy Sheet Fluids
American Letters and Massive Special
Standard Numbers Or System Bar Pipe
Plate Plate
Strip Pipe
20 14 A—U4SG ×
Copper element
containing 2017A A—U4G × ×
aluminum alloy
20 24 A—U4G1 × × × ×
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Jul. 15/2010 Page 1
Appearance of Finished Products

Brand
Brand up
Previously
to France
Alloy Represented Sheet
/American Massive Special Fluids
by Letters or Bar Pipe Thread
Standard Plate Plate SystemPpipe
and Numbers Strip
Copper 2024 PL A—U4G1/A5 ×

element
Containing 2618 A A—U2GN × ×
Aluminum
alloy 2214 A7—U4SG ×
Magnesium
50 86 A—G4MC ×
element
containing
aluminum 5056 A-G5 ×
alloy
Zinc element 7075 A-Z5GU × × ×
containing
aluminum
alloy
20-01-03-101
Jul. 15/2010 Page 2
CHAP-SEC 20-02
20-02-00-P5 1 Jul. 15/2010

20-02-00-P5 2 Jul. 15/2010
20-02-00-P5 3 Jul. 15/2010
20-02-00-P5 4 Jul. 15/2010
20-02-00-P5 5 Jul. 15/2010
20-02-00-P5 6 Jul. 15/2010
20-02-00-P5 7 Jul. 15/2010
20-02-00-P5 8 Jul. 15/2010
20-02-00-P5 9 Jul. 15/2010
20-02-00-P6 1 Jul. 15/2010
20-02-00-P6 2 Jul. 15/2010
20-02-00-P6 3 Jul. 15/2010
20-02-01-101 1 Jul. 15/2010
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GENERAL MAINTENANC AND REPAIR PROCEDURE

TABLE OF CONTENTS

20-02-01-101 Marks
20-02-01-102 Marks
20-02-01-103 Installation of Pipe Line
20-02-01-104 Installation of Rotary Joints on Hydraulic, Fuel,
Ventilation and Oxygen Pipe Lines
20-02-01-105 Description and Application of Pin-board on Aircraft
20-02-01-106 Description and Application of Heat Shrinkable
Self-sealing Sleeve
20-02-01-401 Installation of “US” Hydraulic Joint
20-02-01-402 Installation of “ARSAERO” Hydraulic Joint
20-02-01-403 Installation of “FLEXIRAC” Joint
20-02-01-404 Protective Measures for Installation of Seal on
Mechanical or Hydraulic Units
20-02-01-405 General Description on Installation and Removal of
Magnetic Seals
20-02-01-410 Stripping and Crimping of Cable
20-02-01-411 Binding of Cable
20-02-01-412 Cable Mark
20-02-01-413 Shield of Cable
20-02-01-414 Installation of Heat Shrinkable Self-sealing Sleeve
20-02-01-415 Installation of Cables
20-02-01-416 Repair Procedure of Winding Connection Panel
Components
20-02-01-601 Check Applicable to Detachable “Winding” Section
of Lug Plate Area Connector
20-02-02-101 Aluminum Alloy Heat Treatment
20-02-03-101 Forming of Structural Sheet Metal Part
20-02-03-401 Hot Stamped Center-dot
20-02-03-402 Bottom Swaging Forming
20-02-03-403 Bend Forming
20-02-03-404 Pipe Bend Forming
20-02-03-405 Forming of Lightening Hole and Reinforcing
Center-dot
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GENERAL MAINTENANC AND REPAIR PROCEDURE

TABLE OF CONTENTS
20-02-03-406 Forming
20-02-04-401 Pitch and Edge Distance and Countersunk Hole of Rivet
20-02-04-601 Specification for Riveting Acceptance
20-02-05-101 Connection
20-02-05-102 Identification of Left Handed Thread Assembly Marks
20-02-05-401 Correct Operation for Riveting of Structural Parts
20-02-05-402 Welding
20-02-05-403 Assembling of Bushing on Supporting Part
20-02-05-404 Assembling
20-02-05-601 Check of Self-locking Nuts and Screws
20-02-06-101 General Description on Safety and Lock of Assembly
20-02-06-401 Safety of Shaft Pin
20-02-06-402 Safety with Locking Wire
20-02-06-403 Safety with Locking Plate
20-02-06-404 Safety with Split Pin
20-02-06-405 Locking with Jam Nut or Tooth Washer
20-02-06-406 Peening lock
20-02-06-407 Locking of Slotted Nut
20-02-06-408 Safety of Turn-buckle
20-02-06-409 Security with LOCTITE
20-02-06-411 Locking of Type 4 L/HOTELIER End Connector
20-02-06-412 Locking of Drive System with “SHUR LOCK” Nut
20-02-06-413 Locking of Drive System with “STA LOCK” Nut
20-02-07-101 Bonding
20-02-07-401 Bonding method
20-02-07-402 Bonding on Metal Structure and Honeycomb Panel
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GENERAL MAINTENANCE AND REPAIR PROCEDURE

TATBLE OF CONTENTS
20-02-07-403 Bonding Painting -1318B Varnish or DBLQ-6801 Green

Insulation Varnish
20-02-07-404 Hydrocarbon Based Conducting Grease
20-02-08-101 Installation and Tightening up of Bearing or Self-aligning
Bearing
20-02-08-401 Removal/Installation and Slot or Spherical Tightening up of
Bearing or Self-aligning Bearing
20-02-08-402 Removal, Installation and Clamping of Bearing or Self-aligning
Bearing with Transition Liner and Inserted Washer
20-02-08-403 Removal, Assembly and Rolling Tightening-up of Arc Recess
Bearing
20-02-08-404 Replacement of Unlubricated “DU” Wear Resistant Liner
20-02-08-405 Replacement of ROSAN Liner and Stud
20-02-08-406 Replacement of Inserts in Sandwich Plate
20-02-08-407 Repair of Engine Intake
20-02-08-408 Installation of Engine Intake Strainer Vortex Tube and Conic
Outflow Nozzle
20-02-08-409 Installation and Bonding of Engine Intake Strainer Vortex Tube
and Conic Outflow Nozzle
20-02-08-601 Check before, after Assembling and Tightening of Bearing
20-02-09-602 Penetrant Inspection Method
20-02-09-603 Magnetic Particle Inspection Method
20-02-10-101 Inspection of Baring
20-02-10-401 Removal, Cleaning and Provisional Protective Treatment of
Bearing
20-02-10-601 Detail Rules and Regulations on Bearing Inspection
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MARKS
1 Fluids System Pipe System (Standard NSA.014.10)

T T T T
1.1 General
In accordance with functions and types of the liquids delivered, use different colors and
liquid marks to identify the main marking band and auxiliary marking band as per
functions, and provide the hoses and hard pipes with marks.
—Symbols and colors indicate the general functions of liquids.
— Literal marks describe types and usages of liquid.
— When pipes to be removed require a special protection，it is necessary to use an
auxiliary marking band .
There are two kinds of marking bands：
— Main marking band, marked with liquid type and main function.
—Auxiliary marking band, supplementing the main marking band and providing data.
1.2 Main marking band
The main marking band is comprised of two parts (see detail A in Fig.1).
— The width of 7mm is identified with liquid symbol (1) .
— The width of 18mm is identified with color of liquid characteristics and literal
description (2) on liquid type and use as well as the description (3) in Chinese and
foreign language vertical to marking band. Marks are arranged alternatively one
obverse and one reverse with spacing of about 4mm.
1.3 Auxiliary marking band
Auxiliary marking band (see detail B in Fig.1) is near the colored side of main marking
band.
Fig. 1
They have：
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— When required, (main marking band fails to provide enough information)，literal

description (4) on liquid type and use in Chinese and foreign languages
or
— Characters indicate ：
• Liquid flow direction (5), when there is risk of confusion.
• Hazard mark (6)，when pipe removal requires a special protection.
1.4 Position of marking band
Each pipe should have a marking band ：
— Near the end of pipe (symbols are on the side of the end)
—Spaced by 600mm approximately
At appropriate place, install a marking band，so that with pipe installed，at least one
marking band is installed at the most eye-catching area.
1.5 Marks of hydraulic system (see Fig.2)
(Standard NSA.014.10)
1.5.1 The following are applicable to the color codes in Fig.2
1.5.2 Letters representing hydraulic system marking band (see Fig.2)

a— Fuel；
b— Rocket catalyst； l— Pilot-static system;
c— Spray water； m— Cooling；
d—Compressed air； n— Fire protection；
e—Rocket fuel； o— Power line；
f— Unit propellant； p— Inert liquid；
g— Lubricant； q— Oxygen；
h— Pneumatic control； r— De-icing；
i—Rocket fuel； s— Adjustment- supplemental mark；
j— Solvent； t— Hazard；
k— hydraulic control； u— Flow direction.
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Fig. 2
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MARKS
1 Electric System
1.1 General
Electric system shall use letters and numbers to comprise a mark in accordance with
aeronautical standard AIR 0117/A, to the functions of electric element, subassembly and
assembly.
Integral mark：
— On wire and bundle of wires：
• Black ink printed mark, or
• One or several plastic sleeves printed with marks, or
• Paper tape printed with black mark and covered with protective varnish or transparent
insulating sleeve.
— On the electronic element and equipment, one of the following methods is used：
• Etched light metal sheet (black background with white letters）
• Mark painted with a transparent protection varnish coat
• Black background with white letters
• Adhesive fixed paper applied with a transparent protective paint coat printed with white
background with black letter.
1.2 Network mark
— In the following table, networks are marked with capital letters (letters I and O are not
used) to indicate their functions.
— Network mark (quoted from Aeronautical Standard AIR 0107/A)
A Armament N Negative pole or neutral cable
B Photographing P Low voltage DC power supply and main
C Flight control—control surface distribution system
D Check instruments (except flight Q Control and monitor：fuel, lubricating oil and
instrument F and engine others
instruments E ) R Radio(communication and navigation)
E Engine instrument S Radar
F Flight instrument T Special electric equipment
G Landing gear-brake U Other electric equipment
H Air conditioning- anti-icing V DC power supply cable and control circuit of
AC power supply line
J Ignition W Warning and emergency
K Engine control X AC power supply and main distribution system
L Lighting —signal——display Y Armament—special equipment
M Others Z Special test system
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1.3 Circuit mark

Circuit will be identified by using two capital letters：
—The first letter represents the network that the indicated circuit belongs to.
—The second letter represents all the lines of the network.
Examples：
1.4 Purpose of circuit marking letter

—It is quoted from Aeronautical Standard AIR 0107/A.
Note:
The explanation is only for marking letters of circuit installed in the aircraft. For the
relevant data, refer to the Aeronautical Standard
Network C—Flight Control—Control Surfaces
CA Autopilot CW display—warning
Network D— Instruments
（flight instrument（F）and engine instrument（E）excluded）
DF Outside temperature DW Rotor pitch indication
DG Landing gear position
DH Liquid pressure DW Display-warning
Network E—Engine Instrument

EC Exhaust gas temperature EK Fuel quantity gauge indicator,
fuel level, fuel tank residual fuel
EF Torque meter EM Lubricating oil pressure and
EH Flowmeter temperature
EJ Fuel quantity gauge EU Tachometer
EW Display-warning
Network—F Flight Instrument

FA Turn and bank indicator FB Vertical velocity indicator
FC Directional gyroscope FN Pitot-static tube head heating
FF Compass (including flux gate
and other stabilizing compasses)
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FG Artificial airplane FK Altimeter

horizon-three-axis data FW Display-warning
transmitter
Network G—Landing Gear—Brake—Helicopter Rotor Blade Folding

GA Landing gear control GF Ground safety circuit
GB Landing gear retraction GJ Landing gear uplock
GD Landing gear downlock GL Helicopter rotor parking brake
GW Display- warning
Network H-Air Conditioning-Anti-icing

HE De-icing (general ) HC Heating (cockpit and cabin)
HK Windscreen de-icing HL Outer cover heating
HW Display-warning
Network j-Ignition
JA Ignition coil JW Display-warning
Network K—Engine Control

KK Start KW Display-warning
Network L-Lighting -Signal-Display

LC Cockpit LM Landing light
LE Cabin LN External lighting
Network L-Lighting -Signal-Sisplay

LT Checking light socket
LG Cargo bay LW Display-warning
LH Internal lighting LX Collision avoidance light
LJ Navigation light
LK Instrument —UV signal— red
lighting
Network M—Others
ME Crane ML Hydraulic system
MK Windscreen wiper MW Display—warning
Network P— Low Voltage DC Power Supply and Main Distribution System
PA Generator control PB Generator regulation
PE Battery control PP Main and auxiliary bus bars
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PG Ground power supply socket PQ Converter

PJ Voltmeter PW Display-warning
Network Q-Control and Monitor：Fuel, Lubricating Oil and Others

QF Fuel delivery pump QN Fuel booster pump
QW Display-warning
Network R-Radio (Communication and Navigation)

RA Instrument landing RN VHF-navigation
RC VHF—communication RP Radio— compass
Network R-Radio(Communication and Navigation)

RD Radio signal navigation
RE HF (high frequency) RR UHF
RL (ICS)-earphone, microphone RS VOR-LOC
RM Radio power supply RW Display-warning
Network S-Radar
SA Radio altimeter SH IEF—Transponder
SK IFF—Interrogator
Network U- Other Electric Equipment

（The network marking letter U is used only when letters “R” and “S” are not applicable to
the relevant electric wiring）
UA Utility circuit of electronic UC Utility power supply of several
equipment and electronic system equipment
UB Utility interconnection UW Display-warning
Network W—Warning and Emergency

(Circuits rather than the circuits already mentioned in the various networks)
WA Door switch WM Icing detection
WB Fire extinguisher-fuel cutoff
valve WQ Lubricating oil pressure drop
WE Jettison warning warning
WG Fire alarm control WW Display-warning- fault detecting
Network X-AC Power Supply and Main Distribution System
XD Converter ammeter XP Essential and auxiliary bus bars
XQ Converter XU Converter control
XJ Voltmeter XW Display-warning
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1.5 Wire mark

1.5.1 Wires of DC power supply network
A wire is identified with two letters of the dependent circuit followed by the serial
number comprised of 1 digit or 2 digits.
Example：
Negative wire is identified with wire marking letter followed by letter N .

Example：
C A 2 N
Special case
a) Mark of wire to engine
The wire marking letter is preceded by the numbers that indicate the serial number of
engine.
Example：
b) Common wire mark of several circuit of the same network.

These wires are identified with a single network letter followed by serial number .
Example：
c) Feeding of AC power supply network ，wire marking of control or monitor

equipment.
For these wires of passing through the control circuit, letter V preceded by network
marking letter is to mark the characteristics.
Example：
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1.5.2 Wires of AC power supply network

As all three wires of 3-phase network comprise identical circuits，so they have the same
marking symbols, which are followed by power supply phases A, B or C (letter D
stands for the insulating neutral line of returning to power supply).
Example：
1.6 Marking of stranded cable or wire bundle

All the wires belong to the same network，the composition of bundle mark characters is as
follows：
All the wires belong to the different network，the network mark characters will be
changed to small letter α
Example：α α 23
1.7 Marking of wire segment or bundle
The various lengths of the same wire（or bundle）have the same mark characters as that of
the same wire（or bundle），followed by the capital letter from alphabet E as arranged in
alphabetical order to mark the relevant wire（or bundle ）segments.
When in use，the serial number represents the continuous change number of relevant wire
segment.
Example：
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1.8 Marking of electric equipment，system and sockets

1.8.1 Equipment or system of belonging to the same network
They are marked with：
9 E 3
— Effective reference number selected by aircraft manufactory
(the same component has the same reference number )
— Network marking letter
— Serial number
1.8.2 Equipment common to several networks
Use small letter to replace the network marking letter.
Example：25 α
1.8.3 Electric plug socket
Plugs and sockets are marked with mark characters of equipment，and when one
equipment is provided with several plugs，try as much as possible to identify them from
left and from up to down with small letters as per arrangement in alphabetical order.
Example：
9E3a is the socket installed on the left side of component
9E3b is the socket installed on the right side of component
1.8.4 Wiring equipment (connecting strip, terminal plate, terminal box)
The marks used for them are：
— Serial number
— Capital letter (△)
Example： 24 △
Table 1—List of Wire Marking Method
Use one number to distinguish equipment of the same group
1.2.3 etc.
Example：The same engine, the same radio or armament equipment group is
mandatory, but for other equipment group, it is optional.
This letter is necessary to be use on AC monitor/control circuit or DC control V
wire
Network marking letter
Mandatory A—Z
Circuit marking letter
It is mandatory except for some common wires and wires of test network , of A-2
which the marking letters are not decided yet
One digit or two digits represent a wire number
Wires specified for test network can use three digits 1~99
Mandatory
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A,B,C：means AC power supply phase mark A,B,C

D：Covered neutral of returning to power supply
D：Negative wire or direct grounded neutral followed by wire number D
Mandatory
Letter that represents the order of wire segment E—2

Only when a wire consists of several segments or number of changes must be
identified, it is mandatory to use letter E to represents the first wire segment.
Mandatory N excepted
Digit represents the number of continuous changes of the wire
— 1：First change 1～9
— Original wire segment not marked with number can be made by user’s
own decision
Note: Letters I and O are not to be used.
Table 2—List of Multi-Wire, Cable Strand or Cable Bundle Marking Method
Use digits to distinguish equipment of the same group 1.2.3 etc.

Example：The same engine, the same radio or armament equipment group is
mandatory, but for other equipment group, it is optional.
Special symbols：It is mandatory to use small Greece alphabets to represent a

a cable bundle or stranded cable in the cable.
Letters represent in turn the different segments of cable strand or cable
bundle with the same structure (except for length) E—2
Only when a wire consists of several segments or number of changes must
be identified, it is mandatory to use letter E to represents the first wire
segment. N excepted
It is mandatory for aircraft production in batch..
The number represents the number of continuous changes of structure of all
segments of the stranded cables or cable bundles. 1.2.3 etc.
When a change is made to the structure of some segments among several
segments of stranded cables or cable bundles, the serial number of the
changed segment must be revised. If only the length of some segments is
changed, then the changed segment must be indicated using a revision
symbol.
Optional.
Note :Capital letters I and O are not to be used..
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Table 3 — SUMMARY FOR EQUIPMENT MARKING PROCEDURE
Small letter m represents that the equipment is installed on engines.

If it is used. m
Numbering of items. All the identical items should have the same
numbers 1.2.3 etc.
Mandatory
The network circuit marking letter or small Greek alphabet of the control
A-Z or
items stands for connection of items with several network circuits.
ALPHA
Mandatory
Serial number of identical components having the same number.

No serial number for components in special forms. 1.2.3 etc.
If it is used
These small letters indicate electric receptacles on item that has a few
receptacles are normally arranged from left to right and from up to down.
a—Z
If it is used
Note：Plugs are identified with integral item marking letters, and small letters correspond
with receptacles.
Table 4 — SUMMARY FOR CONNECTOR AND CONNECTING PLUG

MARKING DIRECTIONS
Small letter m represents that the connector or connecting plug is

installed on engines.
m
If it is used
For connecting plugs on a board, serial numbers (to be decided by aircraft

manufacturer) are normally arranged from left to right and from up to
1.2.3 etc.
down.
It is mandatory
Special character (capital Greek letter DELTA) stands for connector or

△
connecting receptacle
DELTA
It is mandatory
Note：Capital letters I & O and small letters 1, 1 are not used.
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INSTALLATION OF PIPE LINE
1 General
1) When the hoses and pipes for transferring hydraulic oil, fuel, air, oxygen and other liquid
are installed onto helicopter, mechanical assembly or accessory, it is required to take
some measures.
2) Different connectors are used in the various systems：
— “AESAERO” connector in hydraulic system.
— “FLEXIRAC” (soft and hard) flexible connector in fuel, fuel tank vent, air
conditioning and engine air intake de-icing system.
— “LeBozec”“VIGOFLEX”，“AIRFLEX” flexible connectors in engine system.
—Standard US (AN) connector to connect US equipment.
2 Installation of pipes
2.1 Check before installation：
a) Check of pipe clip：
Check if the installation pipe clip is correct (pipe clip can not be upside down, and it
should not be installed on the bending portion of pipe).
b) Check of clamping：
Check if the clamping rubber gasket is in optimum position and if it is in a correct
position of support.
c) Equipment check：
Make sure all equipment items are installed，and if it is necessary to remove pipes later
on.
d) Check of aircraft pipe line installation：
Find out if pipe line is convenient for installation，there should be no stress in pipe clip，
and if it is accurately in line with pipe fitting.
Note: In installation, there should be no tension stress，and however，on contrary，there
should be a light compression.
2.2 Preparation prior to pipe installation
2.2.1 Preparation of clips
— Take down clips.
— In clip connection, lightly sand structure (particle size 320).
— Use trichloroethylene to clean the connecting point and dry it.
— Apply pure Petromatum (AIR3565) the contact points.
— Check if clip is clean and reinstall it.
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2.2.2 Preparation of connections

— The fitting surface of connector or surface of self-sealing coupling in contact with
titanium shall be coated with sealing compound 6856F or the sealing should be
carried out by using MINNESOTA with No.473.
— Lubricate threads of nut with the liquid used for the relevant system according to
specific purpose specified in the special description of this system.
Special assembling description：
— In the place where self-sealing coupling is installed, use a red color line to mark the
assembly.
— If there is leakage outside a connector and it can not be removed with the tightening
method，then these seals must be replaced .
Caution：When tightening connector, use an open end wrench to fix the connector
to prevent its rotation.
2.2.3 Preparation of pipe
— Use only high quality tools in good condition.
— Prior to installation，check and test the pipes that are stored less 7 years (sampling
check in random)：
1) Prior to installation, check following conditions：
— Wrapped with plastic cover, and in good condition.
— Fitted with blanking plug, and in good condition.
— Marks and symbols are in compliance with the operating system.
— Visually check visible inner surface, and check pipes for foreign matters. If
suspected, send them to special workshop for scouring in accordance with types
of system.
— Check the thread and support surface condition of end connector and nut and pipe
fitting (free from burrs, scratches and slashes, etc.)
— Except for the above checks, following additional checks are applicable to hoses
of system：
· Check the residual service life in accordance with production date of hoses.
· Check they are free form following defects，for example：
：Rubber skin and protective braid separated from inner pipes or metal case.
：Hardening or hardened.
：Room temperature plastic deformation，which is appeared as cracks on pipes or
upper skin.
：Poor connector or protective treatment condition.
：Poor compression connection quality on hoses with compression connected end
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connector.
：Provide pipes with service life ring，and mark them as given in paragraphs 04～50 .
Caution：If pipes are to be connected immediately, then after checking relevant
surfaces，it is necessary to install blanking plug again immediately .
2.3 Trial fitting of pipes on aircraft (see detail A in Fig.1)
— Check the layout of pipe lines：
• Linearity on clip.
• Channel on baffle plate.
— Check if pipes are rubbing against each other, and at least 10mm is extended out of
unprotected element (screw, nut, stiffener, etc.).
If distance between pipe and element is less than 10mm， then a rubber pad (1) shall
be used to avoid direct contact of pipe with elements.
— check that pipes should be installed stressless on the fixed half clamp plate with cover
removed. If necessary, use proper tools to form again these pipes by a special person.
— Clean all pipe installation surface.
— In installation, there should be no tension stress，and it is better to have a light
compression.
Note: In assembling, check if the pressure test, cleaning and drying is carried out for the
pipe which is cut to a desired length.
2.4 Installing pipes on aircraft
Caution：Unless the pipe will be connected immediately，otherwise the blanking plug
can not be removed.
— Check following items：
• Check if all seal are installed and in good condition.
• With the other end is connection，check if the pipe at the free end is blanked with a plug.
• Connection or tightening at one end should not produce torsional stress on the pipe.
• All the pipe fittings can be freely assembled with hands.
• Installation of pipe should be separated from the work that may produce any tiny
substance, chips or other foreign matters.
Note: In accordance with the property of hydraulic system involved，the pipe polluted by
foreign matters must be sent to a special workshop for cleaning and scouring.
• The connection must be in compliance with relevant document，must keep the direction
of liquid flow，and in any time, marks must visible (refer to task card 20-02-01-101 of
this Manual ).
• Properly tighten the connector.
• After tightening ELCO type connector，check clearance between nut and locknut
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between be at least 1.5mm (if necessary, replace shims).

Note: Install bonding strip or bonding wire in accordance with the requirement specified
in the card 20-02-07-401 in this manual.
2.5 Check after installation of pipes：
• All requirements specified above shall be met.
• When increasing and reducing pressure, there is a little bit flexibility when touching a
pipe.
• Pipes should not be twist installed.
• Pipe marks are visible.
3 Installation of Oxygen System Pipes
Caution：When installing oxygen pipes, the strict cleanliness is required to prevent any
explosion or fire hazard.
— Carry out all checks as specified in Paragraphs 2.2，2.3，2.4，2.5.
— Avoid contact wit grease dirt or flammable materials.
— Wet clean cotton gloves.
— Ensure all tools are clean (free from oil, lubricants, etc).
—Remove the blanking plug only in the last minute before connecting a pipe.
— Prior to assembling，blow pipe with dry nitrogen .
— Apply one of the following products to the external threads (exclusive of initial threads)
(wipe extra paint off).
• LUBRI MOL SPRAY
• GRAPHOIL AQUA OX
— Like hydraulic pipe line，tighten pipe fittings，and lubricating threads should be
considered.
— When replacing oxygen bottle，block the pipe with a blanking lug to prevent pollution.
Note: If the system pipe line is accidentally open：
• Blow pipe line with oxygen.
• Repeat at least 3 times.
• Never connect the oxygen pipe to other air sources.
• Prior to operation, blow oxygen pipe line.
4 Measures Required to Be Taken on Aircraft Installed with Pipe Line System
— Never disturb, hit or scratch pipes.
— Never hang the tools or lamps on a pipe.
—Never walk or seat on a pipe.
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— All pipes of which the protection may be damaged：Use a metal sheet or plywood to
protect them.
— When removing a pipe, a clean blanking plug should be fitted immediately.
— Prior to assembling，scour the elements or pipes in a special workshop in accordance
with the property of hydraulic system.
— When an element or monitoring device is off or bypass test is carried out，never only
loose one end of pip to move the free end, thus causing deformation to the pipe. On
contrary, it is required to loose both ands and connection clip. If necessary, remove the
clip, and then shift the pipe to another proper position.
Pipes, bypass pipes and test equipment must be thoroughly cleaned.
5 Service Life of Synthetic Rubber
Refer tithe following items of task card 20-09-01-902 in this Manual：
— Hose type mark.
— Storage time limit.
— Service life.
• When it is installed on a component，assembly or aircraft, it is required to mark the date of
replacement on collar clamp ring that is fixed to the hose.
The last two digits are year，date is followed by the mark of time limit of replacement.
Example：
Type Ⅲ，Ⅳ or V hose，manufactured in the first quarter, 1973，and installed in first quarter,
1976.
Installation Date Production Date Storage Time
First quarter , 1976 — First quarter, 1973 ＝ 3 years
— The shelf time will determine the residual service time：
• Refer to task card 20-09-01-902 Appendix 2 (chart) in this Manual, storage time is 3 years,
and 7 years and 2 quarters are remained.
— Installation date + residual service life= replacement date to be marked on the ring.
Example：First quarter of1976 +7 1/2 years ＝ PER3T83+6T
5.1 Special case
— If the patented equipment part is provided with a hose not marked with replacement
time, then a mark should be made on the clamp ring when the equipment part is
installed onto aircraft.
5.2 Hoses that have been stored for 7year or more time
It should be tested once a year as required in task card 20-09-01-902 in this Manual to
extend the time of validity.
6 Tying of flexible pipes (see detail B—C in Fig.1)
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Fig. 1
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6.1 Purpose
Tying is aimed at separating the flexible hoses or hoses to prevent rubbing and wearing.
6.2 Requirements for material
— Tying is to tie polyvinyl chloride tape around each hose.
— This PVC tape is to be stored at room temperature (18~20℃).
6.3 Procedure
— Cut the tape into strips with length of 60~70cm according to pipe diameter.
— Wrap it as shown in detail， then fasten the strip, and after fastening, the flexible hoses
should be approximately 8mm apart.
— Tie a common knot and then double knot and firmly fasten it.
— Cut off the tape at point 10mm away from the knot (detail C).
— After wrapping three layers of coils, make sure the tape is firmly fastened and then tie
a knot and keep a clearance of approximately 8mm between hoses.
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INSTALLATION OF ROTARY JOINTS ON HYDRAULIC, FUEL,

VENTILATION AND OXYGEN PIPE LINES
1 General
This task card specifies procedure for installation of rotary joints (for example：Ermeto
BANJO joint).
2 Description (see detail A in Fig.1)
Rotary joint is used to connect a pipe to a fixed part (for example：fuel tank, radiator, etc.).
They include：
— One steel or light alloy casing (1).
— One steel or light alloy hollow bolt (2).
— Two fiber or annealed aluminum gaskets (3).
— Lockwire (4).
Double seat rotary joint are applicable to connect two pipes.
The various methods can be used to connect the rotary joint to pipe：welding，LEBOZEC
soft joint，FLEXIRAC joint, etc..
Fig. 1
3 Assembling of Rotary Joint

3.1 Check if the fitting surface of seal is clean and in good condition.
3.2 Check if thread is clean and in good condition.
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3.3 Check if sealer is in good condition，and properly lubricated as specified in the drawing. If
there are no other specifications on drawing，then carry out lubricate as per the procedures
as follows:
— Hydraulic pipe line：Use hydraulic oil.
— Air or ventilation pipe line with steel screws：Molybdenum disulphite grease.
— Air pipe line with light alloy screws：Use wool grease or petroleum.
— Oxygen pipe line：Apply sealing compound as per 20-01-01-304.
In removal, apply new sealant as mentioned above and carry out reassembling.
3.4 Lubricat threads of screw as per the procedures as follows:
— Hydraulic pipe line：Use hydraulic oil.
— Air or ventilation pipe line with steel screws：Molybdenum disulphite grease.
— Air pipe line with light alloy screws：Use wool grease or petroleum.
— oxygen pipe line：Use lubricating sealing compound.
3.5 Install the element in appropriate position of the pipe using hands. Check if the seal is
placed in the center.
3.6 The load moment value of a hollow screw is specified in the relevant data of aircraft. For
each special case，it is very difficult to determine torque load，which mainly depend on
design of joint, use of fiber or annealed aluminum gaskets, surface cleanliness，and
property of thread and material in use, etc. Therefore, if there is no aircraft moment value
provided in the relevant data of aircraft, then load the moment of force until no leakage
occurs.
3.7 Lockwire or draw an alignment mark.
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DESCRIPTION AND APPLICATION OF PIN-BOARD ON AIRCRAFT
1 General
— Pin-board is used to ensure the interconnection of selected radio navigation and
navigation aids on aircraft.
— The pin-board includes three individual parts:
• The fixed part is installed as the basic equipment part of aircraft, which is used to adapt
the other two disassembly parts.
• The first disassembly part is comprised of selected equipment socket unit which connects
this equipment to the fixed part.
• The second disassembly part is custom-made as per “Covering”. They should be in
accordance with the requirements of selected equipment for aircraft, so as to ensure the
proper connection between different selected equipment and various power sources and
ground wires.
2 Definition of Pin-board
Pin-board is an element, where all the selected interconnection parts have been already
properly arranged. The technology used for connection is “Covering”.
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DESCRIPTION AND APPLICATION OF

HEAT SHRINKABLE SELF-SEALING SLEEVE
1 General
— The heat shrinkable self-sealing sleeve is used to ensure the shielded cable or coaxial
cable can make ground connection (4) at any point on these cables.
— The heat shrinkable self-sealing sleeve should be selected according to cable operation
temperature, wire type and heating mode.
2 Characteristics (see Fig.1)
— self-sealing sleeve consists of the following parts：
• Semi-transparent blue or white heat shrinkable irradiated polyethylene (Kynar) insulation
sleeve (1).
• Automatic etching welded ring (2) located in center of self-sealing sleeve.
• Two thermoplastic seal rings (3) located in each end.
— The effects of following heating (hot air or infrared ) will be different with different
types of self-sealing sleeves (see Table 1)：
• Case shell shrinkage .
• Melting of welded seal ring.
• Melting of thermoplastic seal ring--ensure that it is connected with welding, sealing and
mechanical protection in one operation.
— Required temperatures to obtain these three factors are as follows：
• Temperature for melting of thermoplastic seal ring is about 100℃
• Temperature for shrinkage of insulation sleeve is at least 175℃.
• Temperature for melting of welded ring is about 185℃.
Table 1—Heat Shrinkable Sleeve No. and Assembling Method
D10X-00
D108-XX
Sleeve No. D142—XX D144-XX D10X-31
B013-1X
D10X-31
Shrinking Hot air
Hot air Infrared Infrared
method Infrared
3 Storage Condition
— Keep the heat shrinkable sleeve in the original pack.
— Store it in the dust free cooling place, sheltered from sun shining.
— It is recommended that longest shelf time be 5 years.
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Fig. 1
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INSTALLATION OF “US”HYDRAULIC JOINT

1 “US” Directly Installed Joint
1.1 General
“US” direct mount joint is a fitting that acts as a sealing and connection between
hydraulic element and pipe line.
There are two kinds of direct mount joints for consideration：
— Rotary joint.
— Direct joint.
1.2 Composition
1) Rotary joint includes: (see detail A in Fig.1)
— One joint (1).
— One nut (2).
— One liner bushing (3).
— One O-ring (4).
2) Direct joint includes: (see detail D in Fig.1)
— One joint (1).
— One O-ring (2).
1.3 Installation of “US” direct mount joint
1) Rotary joint：(see details A-B-C in Fig.1)
— Clean joint, nut and boss (5).
— Apply paraphine to joint thread, liner bushing and O-ring or use hydraulic oil in this
system to lubricate them.
— Tighten the nut, and then fit O-ring into slot of the joint.
Caution：Put the smooth face of liner bushing on the side of O-ring.
— Screw in the joint until it is tightly against the threaded portion outside joint (see
detail A)
— Hand tighten the joint (the nut is allowed to rotate with joint) until the O-ring is in
contact with boss (see detail B).
— Fix the nut with a wrench, then tightening the joint by one turn and a half.
— Tighten the joint at most by one turn to determine the position joint.
— Fix the joint, and firmly tighten the nut on boss (see detail C).
Note: The ring can be slightly protruded and no harm will occur.
2) Direct joint includes: (see detail C in Fig.1)
— Clean joint and mount seat (3).
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— Lubricate the joint thread and O-ring (hydraulic oil of an appropriate system).
— Fit O-ring into slot of the join.
— Screw in the joint until it is completely fixed on boss .
Fig. 1
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INSTALLATION “ARSAERO”HYDRAULIC JOINT
1 “ARSAERO” Joint
1.1 General
ARSAERO joint is used for sealing and connection between rigid pipe of various
hydraulic element and pipes joined with them.
1.2 Composition (see Fig.1)
1) Joint consists of following elements：
— One joint (4).
— One steel obtruding cap (3).
— One nut (1) mounted on pipe.
2) Two applicable types of joints ：
a) STANDARD ISO ARSAERO joint including：
—One black obtruding cap.
— Metallic yellow external thread and nut.
b) SPECIAL ISO ARSAERO joint including：
—One metallic yellow obtruding cap.
—One blue nut.
— One black external thread.
This joint is designed to be mounted on secondary annealed and anti-corrosion
Z8CN18 steel rigid pipes.
If the joint is strengthened by steel reinforced bushing (3)，it can be mounted on the
light alloy pipe.
1.3 Installation of ARSAERO joint (see Fig.2)
— Ensure nut (1) can be screwed onto joint (4) with hands.
— Lubricate the nut thread (use hydraulic oil or oil used by pipes). Don’t lubricate
elements of the oxygen system.
— Fit the pipe end (5) into hole of joint (4).
— Screw in the nut (1)，hand tighten the bushing (2).
— Use a wrench to keep on tightening the nut：
• If it is in pressure test pipe line，then tighten by 1/6 turn .
• In its first installation on the aircraft，tighten by 1/6 turn .
• Except that on AG5 pipe of normal diameter (ND) being 32mm or more than 32mm, it
must be tightened by 1/6 turn when it is reassembled，it should be tightened through 30°
while in all other installations.
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The sleeve shown in detail a is “Pre-Tightening”.

The sleeve shown in detail b is “Post-Tightening”.
1.4 Check leakage of joint
— If there is leakage occurred with pipe line pressurized, release the pressure in the
relevant pipe line by screwing out the nut，until the contact between parts is just
disengaged. .
Fig. 1
Fig. 2
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— Contact the part spacing again and tighten nuts through 30°, but pipes AG5 with 32mm
standard diameter or more are not included, which should be tightened by 1/6 turns.
— If leakage goes on, remove the connection, check the contact surface and pipeline
condition. If required, replace the pipe.
Note：
— If leakage occurs, it is prohibited to tighten nuts beyond the specified limits. It is
necessary to remove pipes and check lining.
— If top ring and bushing are in good condition, reinstall pipes properly tighten
connections.
— If the top ring is rose high due to pipe reassembling or caused by too tight installation,
then the pipe must be replaced.
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INSTALLATION OF “FLEXIRAC” JOINT
1 “FLEXIRAC” Flexible Joint

1.1 General
— FLEXIRAC flexible joint is used for fastening coupling between rigid pipes.
— An angle deviation of ±3° is allowable between joint axis and pipe axis, which
depends on the diameter，and it is also allowed to slide within a range between 5.5 and
8.5mm. This allowable sliding value is specified considering the deformation of pipe
under temperature variation.
1.2 Composition
Two types of flexible joints are used ：
— “L” shaped flexible joint is used for connection of two pipe line.
— “E” shaped flexible joint is used for connection between pipe line and equipment.
1) “L” shaped flexible joint includes the following elements：
— O-ring (1).
— Clamping and positioning the retainer (4) of O-ring (1) on pipe.
— Connecting sleeve (5) of pipe line.
— Two half casings (2) are used to fix the flexible joint in a proper position and ensure
pipe can freely slide，and the half casing with flanged edge to retrain the sliding.
— Clamp half casing to sleeve with MINOX clip (3) .
2) “E” shaped flexible joint (see detail Bin Fig.1)
“E” shaped flexible joint includes the following elements：
— One O-ring (1).
— Retainer (5).
— Two half casings (4).
— One MINOX clip (3)；
Sleeve (2) necessary to constitute a integrity with equipment elements.
— It is directly machined as per the element casing，or
— It is directly machined as per adaptor on the element casing.
Note: “L” shaped flexible joint can also be used to connect a pipe to equipment, and
when the latter is equipped with “L” shaped pipe fitting, the connection method
is the same as the connection of two pipes.
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Fig. 1
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1.3 Installation of FLEXIRAC flexible connection (see Fig.2)

1.3.1 General
— Ensure O ring part No. is in compliance with characteristics described by the
relevant system
— Lubricate O ring using given lubricant.
1) “L” flexible connection
— Fit a sleeve onto pipe
— Install the O ring between retainer collars.
— Install the sleeve on the O ring to connect the pipe
— Install half-housing.
— Install and tighten MINX clip.
2) “E” flexible connection
— Install the O ring between pipe retainer collars.
— Install pipe on pipe connection of equipment.
— Install and tighten MINOX clip.
Note: Prior to installation, lubricate the seal：
1) Lubricate the fuel system seal using kerosene or ST.GOBAINS.I.200 grease.
2) Lubricate seals of compressed air (P.2) system using ST.GOBAINS. I200 grease.
Fig. 2
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PROTECTIVE MEASURES FOR INSTALLATION OF SEALS ON

MECHANICAL OR HYDRAULIC UNITS
1 General
— Take the seal out of package only at last minute.
— Check numbering and expiry date of synthetic rubber seal.
Caution：Seals are packed in different types of packing using water proof opaque
sealing device or simple bags，and their life periods are different.
Protective Measures in
Type of Seals Visual Check Prior to Installation
Installation
Liquid or paste sealing -Condition of fitting surface -Use alcohol or acetone to
mixture -Check for dents, scratches or clean fitting surfaces.
-Sealing between two deformation
surfaces
-Products in service：
HYLOMAR-DIVOPAT
-AYPERIX
Felt retainer (dust-proof Prior to assembling, impregnate Check if seals are placed
retainer ) seals using lubricant in grooves
Paper or plastic gasket -Condition of fitting surface (dents， -Use alcohol or acetone to
See detail A in Fig.1 scratches deformation ) clean the fitting
surface bonded seals
-Condition of gasket (notch, -Impregnate non- bonded
tearing, crease) seals in lubricating
oil.
ELCO seal -Condition of fitting surface -Gradually tighten seal
See detail B in Fig.1 (cleanliness, surface roughness ) until there is no leakage，
-Condition of seal (deformation, without
scratches) causing deformation
to seal.
COPPER seal -Condition of fitting surface -Gradually tighten seal
(See detail C in Fig.1) (cleanliness, surface roughness ) until there is no leakage，
-Sealing condition without causing
deformation to seal
FLBER retainer -Condition of fitting surface -Gradually tighten seal

(See detail D in Fig.1) (cleanliness, surface roughness ) until there is no leakage，
without causing
deformation to seal
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Visual Check Prior to Protective Measures in

Type of Seal
Installation Installation
BS ring seal - Condition of fitting surface - Gradually tighten seal
See detail E in Fig.1 (cleanliness, surface until there is no
Item 1-Pre-tightening roughness ) leakage ， without
Item 2-Post- tightening causing deformation to
seal
JACOTFET seal - Condition of fitting surface - Use hydraulic oil to
See detail F in Fig.1 (cleanliness, surface roughness) lubricate seals
- Condition of seal (deformation, - Use specified nstallation
scratches) tools
BAL-seal - ring - Condition of fitting surface - Use hydraulic oil to

See detail G in Fig.1 (cleanliness, surface lubricate seals
roughness ) - Use specified nstallation
tools
Uncut - Condition of fitting surface - Gradually tighten seal
polytetrafluoroethylene (cleanliness , until there is no
PTEE seal surface roughness ) leakage ， without
- Condition of seal (deformation, causing deformation to
scratches) seal.
Bevel polytetrafluoroethylene - Condition of fitting surface - Used for gasket (1) of
(PTEE) seal (cleanliness , O-ring (2) rotating
surface roughness ) under high pressure
See detail H in Fig.1 - Condition of seal (deformation)
- Install the bevel edge of
seal (1) 180℃.
O-ring seal - Condition of seal (wear, check - Use hydraulic oil to
(See detail I in Fig.1) crack) lubricate seals
Caution：when stretched，seal - Adhere seals ：
can not be sprung Use alcohol and acetone
back. to thoroughly clean
- Remove burrs of notch edge or groove and fitting
sharp edges surface
Tool：polished steel scraper - Use the specified tools
Procedure：prior to put seals into - Seals should be placed
slot，prepare scraper. in groove and without
Level the notches around a seal. bending.
QUADRING seal element - This kind of seal element should - Use hydraulic oil to
See detail J in Fig.2 be prevented from being bent, lubricate seals
and include two flanges on - Use the specified tools
each surface of 4 surfaces to assemble and check
if seals are damaged
by tools
20-02-01-404
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（CONT）
Visual Check Prior to Protective Measures in
Type of Seal Installation Installation
- Check condition of seal
(wearing, crack,
deformation)
Caution：when stretched，seal
can not be sprung back.
- Remove burrs of notch edge
or sharp edges
Note：When assembly is not
moved, under certain
condition, a seal can be
adhered to groove.
Single edge seal - Condition of seal flange - Use hydraulic oil to lubricate
See detail K in Fig.2 ( wearing of tip, notching, single edge seals
Double edge seal outwear) - Double edge seal：Use the
See detail L in Fig.2 (1) Good lubricant specified in the
Item 1：Sealing edge (2) Unsatisfactory operation card to fill
Item 2：Spring - Condition of seal mating slit orifice between flanges
Item 3：Closed cell (filled faceted pebble (scuffing, Note：This kind of lubricant
with lubricating oil) corrosion ， scratches, is appropriate with the
Item 4：Dust proof trimming, paint marks) hydraulic oil.
retainer flange Caution ： Seals must be Caution：When fitting
installed in a correct seals，abrasion of seal
direction. mating faceted pebble
should avoided
- Use proper tools. When
possible, Install seals
using pressure
Graphite seal - Condition of seal (print - It should be in compliance

Note：This seal is marks, scratches and chips) with the removal-installation
specially designed for high - Check the spring should not procedure specified in
temperature and high be seized on flange and relevant chapters of the
speed. check the spiral spring to manual.
See detail M in Fig.2 ensure there is a fine axial - Use specified tool for
pressure on the graphite installation and check for
gasket. chips or deformation of seal
- Condition of seal surface - Fingers should not touch the
(print marks, scratches and mating surface or graphite
chips) surface (oxidation)
Magnetic seal - Condition of seal (print - It should be in compliance
See detail N in Fig.2 marks, scratches and chips) with the removal-installation
- Condition of seal surface procedure specified in
(scratches) relevant chapters of the
- Refer to the general manual.
description of installation - Fingers should not touch the
and removal mating surface or graphite
surface (oxidation)
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（CONT）
Visual check prior to Protection measures in
Seal type
installation installation
(20-02-01-405 in the Standard
Practices Manual)
Corrugated seal with friction - Condition of seal (print - It should be in

ring marks, scratches and chips) compliance with the
See detail P in Fig.2 - Condition of seal surface removal-installation
(scratches ) procedure specified in
Item 1 shaft relevant chapters of
Item 2 Corrugated pipe the manual.
Item 3 graphite - Fingers should not touch
the mating surface or
graphite surface
(oxidation)
Corrugated seal - Condition of seal (wear, - It should be in
Note：Sliding and rotating check crack, deformation ) compliance with the
- Condition of fitting surface removal-installation
movement is allowed (cleanliness, surface procedure specified in
See detail Q in Fig.2 roughness) relevant chapters of
the manual.
- Use proper tools, and
check for wearing or
damage.
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Fig. 1
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Fig. 2
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2 Check When Removing Seals

— In removal of seals, care should be taken not to damage chamfers on the supporting
elements or seal support faceted pebble.
— It is required to use the specified tools to install and remove various kinds of seals.
— If there is leakage, replace seals in turn and check condition of seal support faceted
pebbles.
— Before reinstallation of seals, it is necessary to ensure parts seals and tools are clean.
— check causes of leakage：
• Seals：Cracks, deformation or cutting
• Seal retainer：Ceramic material - check for drop-off or convex edges. Metal material -
check for roughness, dents scratches.
— In installation of seal, check that it is not able to turn.
— Before installation if seal is collided with cusp edged surface, it may be damaged during
installation.
3 Allowable Leakage
— Slight leakage generally indicates seals have a good lubrication：If operation is carried
out under a dry environment, rotating or vibrating seals will be damaged very soon due
to abrasion.
— In operation, some rotary seals (graphite, magnetic, corrugated pipes) must allow for a
smooth operation.
— The standard for allowable leakage is specified in aircraft maintenance manual.
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GENERAL DESCRIPTION ON INSTALLATION & REMOVAL OF

MAGNETIC SEALS
1 Requirements for Acceptance

Magnetic seals must be kept in original packing until they are installed.
2 Installation
a) Prior to installation of magnetic seals，clear away foreign matters on sealing retainer
surface. It is necessary to remove bars on chamfer near the seal support boss.
b) Whenever possible, assembling of magnetic seals must be carried out in the clean and
dust free room.
c) After taking seals out of sealed pack，separate rotating elements (airtight retainer) from
non-rotating magnetic ring .
Caution：In order to prevent fitting surface of seal from damage，and sliding of
retainer on magnetic ring is not allowed.
Note: It is required to prevent magnetic rings from being set in a place where metallic
particles are absorbed (chips etc.).
d) Installation of magnetic ring
Cover the properly polished surface using a clean and lint-free cloth，and use hand to fit
the magnetic ring to a sleeve or retainer.
Caution：The magnetic ring can not be reversely installed：Check if its installation
position is correct.
e) Installation of airtight retainer
It is prohibited to use hand hammer to install a thread airtight retainer unit：Impact may
damage seal，causing leakage too early.
Caution：The retainer should be firmly fixed too prevent magnetic attraction
between two seals which may cause a collision between two surface, to
protect the graphite surface airtight retainer from damage.
When installing new seals, before element being separated, impregnate them in hydraulic
oil for 10min.
3 Removal
It is better to use hands to remove a magnetic ring or seal from the retainer，as using a
hammer or any other impact tool may cause crack or damage magnetic ring or O-ring
retainer.
4 Magnetic seal element
(See Detail A in Fig.1)
— Airtight retainer (1)
— O-ring (2), (4) and (5)
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Jul. 15/2010 Page 1
— Rotary ring (6)

— Magnetic ring (3)
See detail B in Fig.1
— Airtight retainer (1)
— O-ring (2) and (4)
— Rotary ring (3)
— Magnetic ring (5)
Fig. 1
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STRIPPING AND CRIMPING OF CABLE
1 Crimping of Cable Terminal Lug

1.1 General
The purpose of this work step is to describe procedure and tools to be used for assembling
or replacing cables and radio equipment cables.
2 Mark and Definition of Terminal Lug
2.1 Lug marking
a) On insulating lug，the color of insulated sleeve is used as mark.
b) Marks shall be made on lug bonding land to indicate size of cable that is assembled on
the lug.
2.2 Lug definition
The definition of a lug includes：
— Its type
— Its size
These items will determine the length and selection of crimping tools of cable to be
stripped：
a) Pre-insulate lugs to be crimped.
— The size will be determined by color of insulated sleeve.
—The type will be determined by shape of the lug.
b) No pre-insulating of the lugs to be crimped
— Size group mark will be on the joint face of lug.
— Its type will be determined by shape of the lug.
3 Procedure (Fig.1)
3.1 Stripping of cable
3.1.1 General
Cable joints, of which crimping joint and stripping of lug is to be carried out
a) Use a special wire stripper.
b) Use a knife.
—The length of cable to be stripped depends on size the lug to be crimped
A：The length to be stripped will be as per type of lug that is used.
B：Cable length to be protruded on the lug joint face：
— 0.8 is used for cross-section of 0.28～8.3mm2 . P P
— 1.6 is used for cross-section of 8.31mm2. P P
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— In case the knife is used for stripping，operators should carefully strip cables to
prevent damage to cores of wire.
Caution：For the cables that have been installed on aircraft, break and fracture
of wire core is prohibited.
3.1.2 Instruction and operation of stripping tool
1) When the wire stripper provided with a removable knife blade for stripping, each
blade should be in compliance with cable cross-section.
2) Operation of wire stripper (see detail B in Fig.1).
a) Determine the length of cable to be stripped.
b) Position the cable on the wire stripper (1).
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Fig. 1
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Jul. 15/2010 Page 3
c) Gently press down the wire stripper，to fix cable on the wire stripper edge (the
cable should be positioned in right angle with knife blade) (2)
d) Check the length of cable being stretched out of knife blade, which should the
same as stripped length.
e) When gradually increasing the pressure on wire stripper，use a knife blade to
circularly cut insulating sheath，and then pull it down the cable，until it is
completely removed (3~4).
3) Stripping with a knife (see detail C in Fig.1)
For cables to be stripped using only one knife，carry out operations as follows ：
a) Cut a shallow circular notch.
b) Cut a deep longitudinal notch in the range of length to be stripped.
c) Use the knife point to fold the longitudinal notch edge，and then cut the circular
notch deeper，so as to tear the sheath down.
d) Check the cable condition (No damage to wire core is allowed).
3.2 Crimping of terminal lug (Fig.2)
3.2.1 General
Lug used for crimping will be performed using a special crimping wire stripper
designed by the lug supplier.
In each type of wire strippers，no matter manual or automatic，there is one set of wire
strippers that are in different sizes and suitable for a specific type of lug.
3.2.2 Operation of crimping wire stripper：
a) Identify lugs to be crimping
b) Select a proper wire stripper.
c) Put a lug in the wire stripper，the end of wiring terminal on joint face edge should be
aligned with dead center of wire stripper.
d) Connect the cut end of stripped cable to the wiring terminal.
If stripped length is correct (detail b)
— The cut end of cable shall be aligned with interruption device provided on the lug ,
to so that ensure the core on lug joint face is 0.8 to 1.6mm longer (it depends on
cross-section of cable )
e) Gently clamp the wire stripper，so as to fix the lug in stead of bending it.
Note: The cable of 0.38mm2 cross-section has a thin insulating covering with external
P P
diameter roughly the same as the internal diameter of wiring terminal, and
therefore insulating covering can be connected to the wiring terminal，and can be
crimping-joined instead of cable metallic core (for the detail, see Fig. a).
To prevent this defect，ensure ：
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Jul. 15/2010 Page 4
a) The length stripped is sufficient，and is in compliance with the value required by

individual sized cable used in operation.
b) Set the cable at the upper dead center of wire stripper，so that it will not be crushed.
Fig. 2
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BINDING OF CABLE
1 Binding Procedure
1.1 Direct laying (see detail A in Fig.1)
Use strap to wind the cable by two turns, so that after the strap closed, the sideward
movement of the strap can be avoided, and then rotate the drum of tool, until the strap is
tensioned through a control tool just before the strap being closed, and over-tension must
be prevented. If such phenomenon occurs, it is necessary to cut and take the damaged
strap from drum，and never use the narrowed strap.
Binding should be normally carried out with a spacing of about 100mm (4 inches)，if the
wire reel is big enough to ensure a proper binding of cable，then it carried out with a
spacing of 75mm (3 inches).
Note: Upon strap “disengaged”, the strap will not be able to slide along the reel, so after
“disengagement” of strap, it is required to firmly pull the strap, then lift up and lay
it on the loose hopping reel.
1.2 T-connector (see detail B in Fig.1). Let the strap pass under the leg of the T- connector,
cross below the opposite leg on top and，and close at top of the T- connector as described
above.
1.3 End plate (no connecting method available) (see detail C in Fig.1).
When it is disengaged at the end plate，no connection is required, and it is necessary to
use a 3mm polytetrafluoroethylene spiral wrapped as specified. If there is a gap，i.e. some
joint bolts need not to be connected, break-away point of cable should be properly
adjusted.
Item (1)：Vertically cut two turns.
Item (2)：3 mm polytetrafluoroethylene tape
1.4 Break-away point of single cable (no connecting method available) (see detail D in Fig.1)
For break-away point of single cable or very small bundle，the break-away point on each
side needs about 2 turns of 3 mm polyfluoroethylene spiral wrapping.
1.5 End plate termination and single cable breaking-away
When the method described in above paragraph1.3 or 1.4 is used，it may appear more
suitable for the area, where larger plate and shied cable join is involved.
1.6 Add cable plate and cable assembly to the existing rack
When cable pivot and cable assembly are overlap laid and fixed in proper position on
aircraft，for example，in case a complete set of work accessories is installed，and fixed to
the basic rack cable pivot，and cable bundle is bound together between connectors，the
existing extra connecting wire shall be cut away and a standard 75~100mm(3 ~4 inches)
allowance should be left on the combined cable assembly.
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Fig. 1
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CABLE MARK
1 Repair or Replacement of Mark Printed Sleeve (Fig.1)

1.1 Purpose
If the normal stretch printing sleeve can not be used, then the replacement sleeve printed
from one side can be used instead, the procedure is as follows：
1.1.1 Diameter of sleeve
Select the diameter so as produce a layer of satisfactory cover, and in case 10mm gluing
is used, it will produce a minimum overlapping layer.
1.1.2 Length of sleeve
Select the length of sleeve, so that when there is no graphic symbol for locating, 10mm
joint free sleeve can be allowed.
1.2 Procedure
1) Longitudinally print replacement sleeve to be cut, then wrap the cable assembly to
ensure a satisfactory overlapping layer.
2) Except for the case of wrapping around cable assembly using a tape, the gluing method
will be used fix the sleeve to a proper position (as per Para.1.1.2)
3) If the clearance between joints exceeds 25mm, except for adhesion point (item b), lap
position should be fixed with adhesive.
In the curing process of adhesive, supplementary joint method or other proper methods
should be used so as to apply pressure to the whole lap length
When the fixing process with adhesive is over, it is required to clean the supplementary
joint places.
Note: The above procedure is not necessarily applicable to individual equivalent sleeve of
T
cable.T
Fig. 1
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SHIELD OF CABLE
1 Prevention of Induction Coil during Cable Shielding Cables

1.1 General
1) If shield slabs are connected together from each end of shield slab，or each end is
grounded, an induction coil will be formed in the line (see detail A in Fig.1).
2) In order to ensure cable shield is completely efficient, the induction coil must be
avoided.
When handling the shield cables，the following preventive measures must be observed.
Note: This standard is not applicable for radio frequency coaxial cable.
1.2 Procedures
a) All shield slabs must be connected to shielded juncture only at one end.
b) All shielded junctures must be in compliance with requirements in paragraph 4.
c) One shield slab and more or one group of shrouding can be connected to one shielded
juncture.
d) If a circuit needs a continuous shielding via a plug and socket circuit breaker or via
terminal plate circuit breaker, it can be obtained by using adjacent pin or lug (See
Fig.2A).
e) Shield slab on DC ground plate or AC ground plate are not necessarily to be grounded.
f) For AC or DC circuit, when a signal returns or ground returns，it is not necessarily to
use shield slab.
g) In order to prevent float grounding，when equipment is connected with equipment，it is
not allowed to connect the shield slab to the joint on the equipment. Likely it is
prohibited to connect the shield slab into plug sleeve.
Note: Fig.1 (detail B) and Fig.2 (details A and B) illustrate the recommended shield
method.
— If an induction coil is not formed, separate property can be combined as required, and
according to the special installation requirement，most of them can be determined.
— If the existing equipment has already been internally connected to grounding which is
used for AC or DC，then any induction coil produced is bound to be reduced to a
minimum degree.
— In order to limit possible interference to a local area, the outside of equipment needs to
be specially arranged.
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Fig. 1
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Jul. 15/2010 Page 2
Fig. 2
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INSTALLATION OF HEAT SHRINKABLE SELF-SEALING SLEEVE
1 General
— For description of self-sealing sleeve，it will be as per process card 20-02-01-106 of this
manual.
—For all installations, it is required to use a sleeve, to which, wire type and section
correspond，and can be heated using hot air or infrared.
2 Equipment Required
Note: The given heater is used only for reference，operators can use a similar device.
— CV1980 type hot air generator provided with PR25 reflector.
— Miniray IR 1759 or IR 3104 type infrared generator，of which the form is a gun provided
with a reflector.
3 Procedure
3.1 Wire preparation - See Fig.1.
3.1.1 Connecting wire (see detail A in Fig.1)
— Strip the 6~7mm sheath from connecting wire.
— Trim the core to separate strands.
3.1.2 Shielded wire
3.1.2.1 Installation on the terminal (see detail B in Fig.1)
— Length L*shown in Fig.1 must be equal to or greater than the length joint.
— It is necessary to be crimped by three times.
— When the wire and sleeve are long enough, the shielded braid layer shall be
crimped backward on itself or crimped on sheath (see detail C in Fig.1).
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Fig. 1
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Jul. 15/2010 Page 2
3.1.2.2 Window shaped orifice connected opening (see detail D in Fig.1)

— In case shielded wire can not be connected in connecting sleeve due to the total
size，then the joint should be arranged outside the sleeve .
— In order to prevent the same place from being risen too much，for all wires，the
sleeves should be provided alternatively at point of 80mm of one wire, and at
point of 120mm of next wire.
— Cut endless groove.
— Remove the sheath，to make one opening of 6~7mm.
— If the sheath can not be disconnected from braided layer，the following
procedures should be used：
• Cut two grooves，with spacing of 6~7mm.
• Cut two symmetric bevel grooves.
• One opening (1) is obtained by removing the insulating layers of these two，then
heat shrinkable pipe(1) shall be installed on shielded wire(2).
3.2 Assembling the connecting wire and sleeve
— Fix the connecting wire and sleeve on the wire.
Note: The connecting wire should be stretched out of “big diameter” end of the sleeve.
— Put the assembly part in reflector of heating system.
— Start machine and pay attention to the following matters：
• Boiling of soldering flux，it should not be confused with melting of soldering joint.
• Sheath starts to shrink.
• Melting of plastic ring.
— Continue to heat, pay attention the moment when the soldering liquid wetting the wire,
the wire will present a glossy appearance
Note: Destruction of ring at the beginning of heating stage does not indicate melting of
flux.
— As the sleeve shrinks, it will cause material of seal ring to flow out, and the blue or
white out flowing should not be scraped off.
— As soon as the above operation is completed, move the assembly part immediately
away from reflector.
Note: The heating time varies with the property of sleeve and wire in use.
3.3 Final assembling (see detail E in Fig.1)
— Unless otherwise specified, the wire should form a ring as shown in detail E.
4 Check of Soldering Joint (see Fig.2)
— Check the appearance as the criteria given in the following table.
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• Proper soldering mildness：Smooth appearance.

• If heat is inadequate or overheated，no flux flows，and no long stranded wire is extended
out of sleeve .
• Check the insulation between wire core and ground connector on a line test equipment，.
• Apply 500V DC voltage for one minute，and the resistance should be greater than 20 Mega
ohm.
• Use hand to a pull force to connecting wire of ground wire，check the strength of assembly
part.
4.1 Use the braided layer of self-sealing sleeve for connection
Fig. 2
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— Rejection Criterion (see details A—B in Fig.2)

Note: If one of the following conditions is found by checking, the connector is to be
rejected.
First possibility (insufficient heated assembly)
(1) Seal ring is not molten.
(2) No distinguishing can be made as discoloration of soldering flux end is started
(3) The soldering flux ring has not completely lost its original form.
Second possibility (overheated assembly)
(4) The sheath of connecting wire is damaged as it is overheated, and soldered joint is no
longer visible as the sheath is blackened.
(5) Solder wire can not be seen any more between braided layer and connection wire
strand.
Acceptance Criterion (see details C—D in Figure)
Note: If all the following requirements are met, the connection is satisfactory.
First possibility (assembly under minimum acceptable heating temperature)
(6) Seal bushing has been molten and flown out down the wire.
(7) The soldering flux ring has lost all original edges.
(8) Mesh grid and connection wire strand is visible.
(9) Solder wire can be seen between mesh grid and connection wire strand.
Second possibility (assembly under maximum acceptable heating temperature)
(10) Solder wire is clearly visible between mesh grid and connection wire strand.
(11) Although the sheath is blackened, soldered joint is visible.
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INSTALLATION OF CABLES
1 Installation of Cable Bundle

1.1 General
The instructions provided below is about preventive measures should be taken for
installation cable bundles.
1.2 Cable bundle
1.2.1 Combination and laying of cable bundle (see detail A in Fig.1)
— In order to be easy in installation and maintenance，cable bundle should be
comprised of cables in parallel to each other. Wrapped cable or cable extended out
of wire bundle is prohibited.
— Generally, all unshielded strand cable should be arranged outside the wire bundle.
— Cable (3) should be at least 150mm away from equipment (1) of pipe. If the distance
can not be ensured, then, the distance of from pipe to determined (2) cable edge can
be reduced to 50 mm.
Note: For determination of this distance，the pipe connection and sleeve should not be
taken into consideration.
— Coupling sleeve should be installed in cross hole of wire bundle. A fixing clamp
should be used to clamp the wire bundle together, and then use the same clip for
installation. The maximum distance between structural connecting points should be
600mm.
— For two or more wire bundles, edge of distance holes shall be lower than 2mm.
— Wire bundle should be ensured to be far away from hot surface, so as to prevent
damage to insulation.
— Install and locate the cable，and even make them be easy in service.
— Never use a power distribution line and operation circuit to combine a feed line.
— Observe as much as possible the curvature radius of line or coaxial cable.
Under normal case：
Minimum radius R is 10 times equal to line or cable diameter.
In box or board，if necessary：
Under the case that cable is properly supported：
— Twin wire coaxial cable should be vertically bent to the plane common to two
cables.
— Cable slack requirement
— Cable (including coaxial cable) should be slightly slacked for following reasons.
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• Be easy in installation and maintenance.

• Considering the replacement of two end parts (connector, lug).
• Circuits.
• To prevent vibration from affect on the stress of equipment, or cable supports and
connector.
Note: In some special cases，the residual length of cable bundle should be specified on
drawings.
— Cable length of coaxial cable group should always be the length specified in
drawings. When the cable repair demand is not enough，replace the whole cable .
—Requirement for loop
• A loop is necessary in the areas where liquid drop formed due to condensation or
leakage is brought along a cable to the cable joint. The loop should be provided to
protect accessories from damage by the liquid drops.
— Cable anti-corrosion protective measures. The cables or wire bundles that are easily
damage due to structure abrasion should be protected by using a rubber wire to tie
up them in a required length.
1.2.2 Clamping cables (see detail B in Fig.1)
— In normal condition, cable should be clamped to prevent corrosion.
— Clip should be selected in accordance with the diameter of wire bundle.
— When a clamping device is completely closed, the clamping device should be
clamped without deformation and connecting hole should not be elongated.
— As long as possible, locate the clamping devices so that they can be attached to the
cable bundle. The area provided with clamping device should be most effectively
probe most effectively protect the cable bundle from structural abrasion.
— Cable should not be clamped between two clamping fixed columns (a).
— Clamping device should completely closed (b).
Note: If a proper size clamping device is not available，then select a clamping device,
which is slight greater than the cable diameter.
— Adhesive tape should be wrapped around cable bundle，so that after clamping device
installed，a rated clamping can be obtained. This method can be used only in very
rare cases.
— The distance between two continuous clamping devices should not exceed 600mm.
— Over-clamping of coaxial cable should be avoided, so as to protect these cables
against deformation.
—Following components should be used to protect the clamping stop screw.
• Use the caption or non-caption lock nut.
• Use the lock washer.
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• A flat washer must be placed between screw head and clamping mounting column.
1.2.3 Binding a cable bundle
— Binding a cable bundle：
• To comprise a cable bundle.
• To allocate the mechanical stress to all the cables.
• To combine cables of the same wire bundle，i.e., separate them from the cables of
other wire bundle.
• To facilitate the installation and maintenance.
— Use the following material to bind the cable bundle：
• In all cases, use nylon 11 polyamide fiber tape.
• Hemp wire used for temporary retaining (to bind the wire bundle at outlet of plate or
when nylon 11 can not be used).
— The binding position on a wire bundle depends on the required form and stability.
— However，on the single wire bundle，the distance between two bindings should be
approximately 150mm.
For the fixed wire bundle，this distance can be reduce to 50mm.
1.3 Preventive measures and protective measures for wire bundle and connector.
1.3.1 General
The wire bundle should be protected to prevent any damages.
For this end：
— Avoid contact of harness with sharp edges.
— Don’t step on or sit on harness.
— When displacing cable bundles, convey them instead of pulling.
— For permanent or temporary storage, cable bundle should be laid up instead of
hanging.
— When removing, provide electric plugs with protective cover, and keep such
protective status till installation.
— The non-connection connectors of circuits on aircraft should be insulated by using
colorless insulation casing pipe, of which the diameter is the same as that of insulated
wire.
1.4 Cleaning of installed cables
1.4.1 Materials required
— Plastic Glyst products provided by France TORCO Company have no adverse affect
on the following products:
• Plexiglas.
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• Epoxy prime
• Cellulose or vinyl paint outer painting
1.4.2 Steps
— Put the product on a lint-free clean dry wiper.
— Use this wiper to wipe the outer surface of cable for applying a thin coat of the
product, (wipe clean cable about 1 meter) to allow this kind of product to have a
few seconds of effect.
— Use a lint-free clean dry wiper to remove such product through wiping the cable
from beginning to the end.
Note: In case cable is seriously contaminated, repeat this procedure until all
contaminants are removed.
Fig. 1
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REPAIR PROCEDURE OF
WINDING CONNECTION PANEL COMPONENTS
1 General
When winding is partly or completely damaged, there are two possibilities：
(1) The winding is not repairable or the repair procedure for winding is too complicated.
(2) The winding is repairable and repair procedure is feasible.
2 Winding repair procedure
2.1 Equipment required
2.1.1 Tools
— Electrical standard tool
— Manual winding machine, Part No.：GARAER-DE-NVER 50.5214or similar tool (A).
— Stripping tool, Part No.：GARNER-DENVER 52.5654, or similar tool (B).
— Coil winder, Part No.：GARNER-DENVER 27.650AB7or 27.600AB2, or similar tool (C).
— Winding machine pin, Part No.：GARNER-DENVER 50.9278, or similar part (D).
— Winding machine guide, Part No.：GARNER-DENVER 50.7100, or similar part (E).
2.1.2 Materials
— Removal PR 1005 L.
— Methyl ketone (MEK).
2.2 Procedure
2.2.1 Winding is not repairable or the repair procedure for winding is too complicated：
— In nay cases, replacement is to be done.
2.2.2 Winding is repairable and repair procedure is feasible：
Note: Besides, as a small repair process, soft soldering is allowable, and 4 times of
soldering are allowed at both interconnection points.
— Prior to all repair procedures：
• Use methyl ketone for removal PR 1005 L protection treatment.
— All repair procedures must be carried out by using proper technological equipment：
• Use tool (A) to disconnect the wound connector.
• Use tool (C—D—E) to obtain a new connector on the cable to be wound.
• Use tool (B) to strip the cable on the length required by winding.
— Add or remove connectors in accordance with the table that is in compliance with new
aircraft condition. The part of removable winding should be identified with a change mark.
2.3 Check of winding
According to the task card No. 20-02-01-601, use visual check and optic system check
procedures.
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CHECK APPLICABLE TO DETACHABLE “WINDING” SECTION OF

LUG PLATE AREA CONNECTOR
1 Visual Check
Check the followings：
— Check if electric wire and electric line is in compliance with wiring diagram specified in
the document.
— Check the installed electric wire should be free from neither tension nor stress.
— Random check if the tools used have damaged the wire insulation portion nearby the
wiring terminal.
— Check if the general mechanical condition and cleanliness condition of wiring is
qualified.
2 Check with Optical System (magnification power 3~10)
Check connectors for defects：
— Strengthening connector (see detail A in Fig.1)
• For wire wound with insufficient insulation or with ineffective insulation，at least three
turns should be wrapped on the edge of wiring terminal.
— Final connector (see detail B in Fig.1)
• Connector is too near from the free end of wiring terminal to be able to complete
installation.
• Distance between the wrapped end and the beginning of bevel on wiring terminal at least
should not be less than diameter of bare conductor.
—Strengthening connection (see detail C in Fig.1)
• The first splicing turn of covered wire should not be wound around the last splicing turn
below it.
— Inadequate splicing of wire (see detail D in Fig.1)
• Inadequate number of winded wire.
— End protrusion (see detail E and detail F in Fig.1)
• The total size of wire end protrusion winded area size should not exceed diameter of a
wire， limit of wiring terminal arranged on the detail F slotted pale is 2.54mm, spacing or
AB is equal to or smaller than d.
— Overlap winding (see detail G in Fig.1)
— The first winding shall be in contact with mounting side of wiring terminal (see detail H
and detail I in Fig.1) or be in contact with flux (see detail J inFig.1)
• The pore space or gap between the first winding and wiring terminal bottom (bar H with
shoulder or bar I without shoulder or bar J with tin soldering joint) must be equal to
diameter of wire insulation.
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— Clearance between defective windings (see detail K in Fig.1)

• Maximum clearance between adjacent wire windings：For wire of 0.4-1mm，it is not
allowed to exceed 0.1mm；For wire of 0.2～0.32mm，it is not allowed to exceed 0.05 mm.
— Winding direction and placement method of lead out wire connector see detail L in
Fig.1)
Fig. 1
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ALUMINUM ALLOY HEAT TREATMENT
1 General
The purpose of this section is to provide the user with instructions necessary for some heat
treatment and forming technology required in structure repair.
2 Aluminum Alloy Heat Treatment
2.1 Classification of aluminum alloy
Aluminum alloy in divided into two kinds：
— None- heat treatment alloy (condition “H”)
— Heat treatment alloy (condition “T”)
The phrase of “heat treatment or none-heat treatment ” can be changed to “precipitation
hardening or none- precipitation hardening”，and the latter is more suitable.
The mechanical performance of none-heat treated alloy can be varied through clod
working such as rolling, stretching and metal machining.
Stress produced by cold working can be release via annealing.
This is the only heat treatment procedure used for such alloys.
The mechanical performance of heat treated alloy can be modified by following
procedure：
— Cold working；
— Heat treatment；
— Cold working + heat treatment .
The mechanical performance of heat treated alloy can be modified by following treatment
procedures：
— Quenching + natural aging(in the environmental temperature)：
— Quenching + manual aging (high than the environmental temperature).
For example：
Any quenching or annealing treatment has released effect of the final cold working，which
will cause reduction to the yield strength.
As for 2017A alclad alloy，the standard value of yield strength is reduced from 265Mp to
235Mp (from 27 to 24kg/mm)；as for 2024, including alloy，the standard value of yield
strength is reduced from 314Mp to 275Mp (32~28k8/mm).
2.2 Quenching
2.2.1 General
quenching aluminum alloy including two steps：
— Solution heating, soaking；
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— Cooling (generally, quick cooling in water).

2.2.1.1 Solution treatment and quenching
— solution treatment can be conducted in the following furnaces：
• Circulating air furnace：
• Salt bath furnace.
Note: Salt bath ingredient：It has 308℃ melting point，and active in 500℃,
non-evaporating sodium nitrate.
— Under two conditions，the temperature are same, while the holding time is
different.
— For the solution treatment temperature，see Table 1；For the holding time, see
Table 2.
— In heating，some alloy texture is easier to be dissolved to solid solution than that
in cold condition. That is why the step of quenching is called the “solution
treatment ”.
— By quick cooling，there is no time for solid solution to be resolved，so this
texture of high temperature is fixed under cooling condition.
— Upon quenching，the metal in under softened condition. After solution treatment
(status “AQ”) it is easy in machining.
— The solution treatment needs certain time and temperature，and this temperature
and time varies in accordance with alloy and its previous treatment condition.
2.2.2 Rivet 2017A shall be quenched using salt bath furnace and air furnace.
Rivet 2017A should be quenched with salt bath furnace under following conditions：
— The salt bath temperature is 495±5℃；
— For rivet diameter of 1.6~2.4, the holding time in salt bath furnace is 20~40minutes；
— The quantity of rivet baskets should not be over-charged into furnace, so as to
prevent the temperature from dropping down.
If such case occurs, specified temperature of the salt bath should be recovered within 5
min.
The quenching of 2017A rivet using air furnace should be carried out under following
condition：
— Furnace temperature 490~5℃；
— Holding time：
• For the rivet with diameter of lower than 5mm, it should be 15 min；
• For the rivet with diameter of more than 5mm, it should be 25 min.
Caution：No matter the rivet size，the above holding time is calculated only
starting from the moment when the furnace temperature has reached
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490℃±5℃.
Table 1 Solution Treatment Temperature

Alloy Temperature (℃)
2017A 495 ±5
2024 495 ±5
2618A 495 ±5
France 6081 530 ±5
2014 500 ±5
7075 470 ±5
Table 2 Holding Time (Applicable to Solution Treatment of All Alloys)

Time (Minute)
Thickness of Sheet (mm)
Air Furnace Salt Bath Furnace
0.8 25 20
0.8~2.5 35 30
2.5 50 40
2.2.3 Quenching of alclad sheet

2.2.3.1 Solution treatment time
— Solution treatment should not exceed：
• Thickness of lower than 0.8mm 10 min
• Thickness of 0.8~2.5mm 15 min
• Thickness of greater than 2.5mm 30 min
— Number of solution treatments (exclusive of solution treatment performed by
the seller), at most twice.
Note: For forgings and die forgings, particularly for large sized and complex
shaped components，it is required to pre-specify optimum temperature and
holding time .
2.2.3.2 Transfer time from furnace to quenching tank
—Transfer time from furnace to quenching tank should be measured；
• For air furnace，the measurement starts from the moment when the furnace door
is completely open；
• For salt bath furnace，the measurement starts from the moment when material
edge is first exposed out of salt bath furnace
.
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Table 3 Transfer Time

Thickness of Sheet (mm) Time (s)
e≤0.6 5
0.6~0.8 7
0.8~2.5 10
>2.5 20
2.2.3.3 Quenching water temperature

Table 4 Quenching Water Temperature
Temperature (℃)
Alloy
(As per cross-section)
France 2017A 10~35
2024 10~35
2618A 20±10
6081 10~35
6061 10~35
7075 10~35
Caution：Temperature shown in Table 3 and Table 4 are also applicable for

forgings and die forgings.
— Quenching tank should have an enough volume, so as to prevent the
temperature rise caused by heat transfer as the temperature exceeding 10℃.
— Parts should be soaked as vertically as possible，and the thickest section should
be soaked.
2.3 Aging
2.3.1 Natural aging (status “T4”)
After quenching, the similar ingredients will start to precipitate in a fine grained status
inside the grain. And after that, the metal is hardened to obtain its final
performance. In case the precipitation occurs in a environmental temperature，it is
called a natural aging，and then metal aging is hardened (status“T4”).
2.3.2 Manual aging or tempering (status “T6”)
Under environmental temperature, some alloys are very slowly hardened，and it must
be heated for certain time (110~200℃，6~25 hours ).
2.3.3 Tempering —holding temperature and time
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Table 5 Tempering —Holding Temperature and Time

Alloy Temperature(℃) Time (H)
2014 160±5 19~22
7075 135±5 12~16
France 2618A 190±5 16~18
6061 170±5 4~10
6081 170±5 7~9
2.4 Annealing
Annealing generally is carried out in the air furnace.
Actually, two kinds of annealing are used：
— Stress relief annealing：
— Fully annealing (status “0”)
2.4.1 Stress relief annealing
Annealing can be used to release the stress caused by cold working.
It is that heats metal for short time under re-crystallization temperature.
Annealing can also soften the heat treatment hardened material.
For all heat treated alloys，under temperature of 340±10℃ for holding time of 30~60
minutes，perform stress relief annealing.
Cooling in the indoor air
2.4.2 Full annealing or annealing ( “0”)
Full annealing is to provide a maximum softening to the heat treatment hardened alloy.
Use the temperature higher than and time longer than that of stress relief annealing to
heat the metal, and slowly cool it.
Temperature shall increase as quick as possible.(furnace can not be overloaded).
Furnace is cooled in a rate of 25℃/h to 250℃，and then, it is cooled in the indoor air
(heat treated alloy).
The full annealing can also make the cold working hardened alloy be softened at
maximum.
Holding temperature and time is given in Table 6.
For non-heat treatment alloy 1050A，it must be quickly cooled (water or room
temperature).
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Table 6 Tempering —Holding Temperature and Time

Alloy Temperature(℃) Time (H)
1050A 325±10 15 minutes
2017A 400±10 1 hour
2024 400±10 1 hour
France 2014 400±10 1 hour
7075 400±10 1 hour
2618A Annealing is prohibited 1 hour
6061 400±10 1 hour
Note: For thick parts，holding time should be longer .

2.5 Defects caused by heat treatment
2.5.1 Unsatisfactory performance
Reasons：
— Solution treatment temperature is incorrect (too high：overburn，or too low：
incomplete solution treatment )；
—Holding time is too short；
—Transfer time from furnace to quenching tank is too long；
— Cooling rate is too slow (high water temperature quenching)；
— Tempering temperature or time is incorrect.
2.5.2 Alclad alloy-copper is diffused to alclad
— When alclad alloy is heated to above 400℃，alloy element，particularly copper is
diffused to alclad.
— The presence of copper remarkably weakens the corrosion resistance of alclad.
Therefore, this is additional reason for restrict limitation of number of quenching
and tempering treatments.
— For particularly metal sheet，as alclad thickness is very small，the copper will be
diffused very fast to surface，if these metal sheet undergo several times of heat
treatment，or if one heat treatment is carried out incorrectly, which will give a false
appearance of forming a protective layer.
2.5.3 Blister
During quenching，a blister sometimes appears on a metal surface. On a cladding or
non-cladded thin sheet and massive plate，these blisters on extruded section and forging
may be caused by two reasons as follows：
— Hydrogen or various kinds of impurities are present in the metal (hydrogen is the
only gas that can be prominently dissolved in aluminum alloy)；
— Because alclad material is incorrectly bonded between the center portion and
cladding during the hot-rolling time.
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Presence in metal may be due to:

— Casting with excessive quantity gas；
— Overheated in wet atmosphere.
As the latter phenomenon may occur in quenching furnace, so it can be eliminated by
adding sodium fluorate to reduce the relative humidity in furnace.
2.6 Requirement for heating of hot-forming aluminum alloy parts
2.6.1 This section specifies the requirement for heating of hot-forming aluminum alloy parts
under a low temperature，i.e. under the temperature in which the original mechanical
performance of the metal is not much changed. This procedure is mainly used for local
forming (bending，dimpling etc. )of component with large diameter. Therefore, the heat
treatment of whole formed and assembled big component should be avoided.
2.6.2 Scope of application
— Hot-forming must be carried out for high yield strength alloy：
2014 heat aged alloy
7075 heat aged alloy
— For other wrought alloys 2017A 2024 1050A，hot-forming is not necessary carried
out；however, because it can obtain relatively good forming (in hot state, the elastic
aftereffect will be reduced ) and crackles components，it is recommended to use this
procedure：
— Under the situation of high yield strength alloy，before heat aging (tempering) or
after，forming can be performed, first of all, solution treatment will be more
beneficial. However, its application is limited to the component to be heat treated
during manufacturing.
Under the situation of non- tempering metal，after heating，mechanical performance
will be lowered quickly. Under such condition, the metal should be machined in the
temperature as described in Paragraph 2.4；
— High temperature tempered alloy presents higher hot stretching performance than
that of natural aging alloys (Fig.1).
The chart shows mechanical performance approximation that varies with temperature.
— Hot-forming at low temperature is mainly carried out in the following situation：
• Bottom swaging of press forming，bedding or rolling section material；
• Dimpling prior to riveting；
• Low amplitude forming (lower than yield strength)；
• Correction of deformed component during processing (via deformation or stress relief
annealing)；
• Correction of stamping formed or bending formed component (via deformation or
stress relief annealing).
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2.6.3 Heating mode

— Parts can be heated under the following condition：
• Parts heating，tool cooling (Method a)；
• Parts are heated and tool heated (method “b”)；
• Cooled parts are heated by contact with hot tools (method “d”)；
• Cooled parts are mounted on cooling tool, assembly for heating in furnace (method
“c”)；
— The method to be selected depends on machining to be performed.
— For thin section material (fast deformation ) undercut on mechanical or spiral press
machine，method “a” should be used. Under the same condition，except for the same
very thin section material, method “c” may be used.
— For dimpling sheet or plate，method “c” should be used. Method “d” should be used
for low amplitude forming and straightening of machine parts and die pressed parts.
For press formed parts, method “b” should be used.
2.6.4 Heating temperature and time
— The heating temperature and time should be selected according to machining
condition，properly reducing the time needs to provide a higher temperature (a
better forming condition).
— Generally，the time depends on processing conditions, such as the total size of parts,
distance from tools to furnace, and depends on machine tools (mechanical press
machine or hydraulic press).
The weights of parts and tools and heating method (see Paragraph 2.6.3) can also affect
the heating time .
— In case of releasing the work stress，the heating time should be long enough. In any
cases, if the temperature and time is exceeded，it is necessary to request the design
organization for approval. In case of rejection, parts should be subject to a complete
set heat treatment (if applicable，quenching and tempering).
— If use all necessary preventive measures to prevent parts temperature from
exceeding the maximum values specified in Table 7 (ratio of weight of parts to
operating time)，the temperature tool can be much higher.
Note: For spinning (very short machining time，selected heating zone)，tools should be
heated to about 300℃.
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Table 7 Heating Temperature and Time of Forming

2024 2014 tempering 7075 tempering
Process Temperature Max. Temperature Max. Temperature Max.
±5℃ Time ±5℃ Time ±5℃ Time
Bottom swaging 180 15min 180 15 min. 170 15min
Shaping 170 60min 170 60min 150 60min
Bending 180 >1min 180 >1min 175 >1min

Dimpling
Correcting and 150 10 hours 150 10 hours 135 10 hours

stress relief
forming
2.6.5 Preprocessing prior to parts forming

Under such forming condition of involving the large component deformation (bottom
swaging，spinning, etc.)，any possible reason of incipient crack should be avoided：
— For bottom swaging press formed parts：
• Remove sharp edges；
Grind extrusion scratches；
• Never drill parts before forming.
— For spinning：
• Remove bars from rivet hole.
2.6.6 Heating equipment
— The heating can be carried out by using equipment as follows:
• Fume extraction measures should be taken for air furnace.
• Fume extraction measures should be taken for salt bath furnace.
• Fume extraction measures should be taken for oil tank.
• Heating resistor (tools or parts heating).
• Infrared lamp.
2.6.7 Control in the manufacture period
All heating tools should have automatic temperature control unit, to prevent exceeding
the specified temperature.
Parts temperature should be controlled by using a pyrometer，hot measurement paint or
pencil thermometer .
In some cases (for example: dimple)，temperature of apart can be indirectly controlled
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using the heating time (automatic control should be tried as much as possible ).
Indirect control should be use only under the situation that temperature rising speed is
known (depends on heating method)，and before operation starting, a calibration test
must be conducted.
2.6.8 Post forming inspection
Check all the formed parts，particularly the parts of large area deformation (bottom
swaging, spinning) for cracks.
Fig. 1
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FORMING OF STRUCTURAL SHEET METAL PART
1 General
In repairing of structure sheet metal work, various kinds of forming procedures to be carried
out are as follows：
— Bending, bottom swaging stamping, lightening hole and strengthening center-dot, elbow
(these procedures may use cold- forming), center-dot (this forming procedure should use
hot forming).
For high temperature strength alloy (2014-duraluminium, 7075-super-strength duralumin),
they must be hot formed.
For other alloys (2017A-wrought aluminum, 2024-duraluminium, 5052 and 5056- anti-rust
aluminum), generally, the hot-forming is not necessary to be carried out, but it is actively
recommended to perform hot-forming, because forming in such a way is easy, crackles, and
less resilience.
2 Pre-forming heat treatment
Prior to forming, the material to be formed or in some cases, after forming, a heat treatment
process as follows：
— Quenching treatment
— Annealing
If the above two heat treatments are carried out, then operator must follow specifications
and description stipulated in Chap-Sec-Sub 20-02-02-101 of Standard Practices Manual.
3 Cold-forming
— Bending, bottom swaging stamping, lightening hole and strengthening center-dot, elbow.
These different forming procedures may use dies made of wood, plastic, aluminum, steel to
perform manual forming, and also can carry out forming, by means of dies, on machine
tools such as bender, center-dot stamping press, punch machine and hydraulic press.
4 Bend corner-rounding radius
Bend corner-rounding radius “r” depends on material thickness “e” of the part to be bent
and the size should be selected as specified in Table 20-02-03-403 in Standard Practices
Manual.
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HOT STAMPED CENTER-DOT
1 Center-Dot
1.1 Hot stamped center-dot
— Requirements for center-dot stamping: maximum thickness of a part to be stamped is
0.8mm, if the thickness exceeds this value, then center-dot pricking shall be used, and
in this case, it is prohibited to use center-dot stamping press for center-dot stamping.
2 Center-dot stamping process
The center-dot stamping should be carried out by using a stationary or portable center-dot
stamping press. Center-dot stamping angle will be dependable on the angle of connected
part head (100—120℃).
2.1 Center-dot stamping method (see Fig.1)
— Heating temperature and time.
The heating temperature of punch head for center-dot stamping is 350℃. The temperature
of aluminum alloy metal sheet is 180℃.
Caution: In order to eliminate cracks, observe the temperature of the latter as
carefully as possible.
Heating time depends on thickness of the part to be center-dot stamped.
2.2 Punch die (see Fig.1)
The angle of center-dot stamping male die (1) should be in compliance with that of female
die (2), and be in conformity with various head forms of rivets or bolts on the part (3).
Fig. 1
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BOTTOM SWAGING FORMING
1 Bottom Swaging of Aluminum Alloy Sheet

1.1 General
Bottom swaging of any aluminum alloys should be performed on quench annealed parts
as specified in 20-02-02-101 in the Standard Practices Manual.
2 Determination of Bottom Swaging Size, as per thickness of metal sheet material (see
detail A in Fig.1)
Fig. 1
From 0.8 1.1 1.6 2.1 3.1 4.1 5.1 6.1 7.1 8.6 10.1
e S
1 1.5 2 3 4 5 6 7 8.5 10 12
to
R 1 1 1.6 2 2.5 3 4 5 5 6 8
0.6
H 2.2 2.6 3.5 4.5 5.6 6.6 8.4 10.2 10.6 12.7 16.2
R 1 1 1.6 2 2.5 3 4 5 5 6 8
0.8
H 2.5 2.8 3.7 4.8 5.8 6.9 8.6 10.5 10.9 12.8 16.5
R 1 1.6 2 2.5 3 4 5 6 6 8 8
1
H 2.6 3.5 4.4 5.6 6.7 8.5 10.2 11.9 12.8 15.9 16.7
R 1.6 1.6 2 2.5 3 4 5 6 6 8 8

1.2
H 3.2 3.7 4.6 5.8 6.9 8.7 10.4 12.1 12.8 16.1 16.9
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R 2 2 2.5 3 3 4 5 6 6 8 8
1.6
H 3.7 4.3 5.2 6.5 7.2 8.9 10.7 12.4 13.1 16.3 17.2
R 2.5 2.5 3 3 4 4 5 6 6 8 8
2
H 4.2 4.9 5.9 6.8 8.6 9.2 11 12.7 13.5 16.8 17.6
R 3.5 3.5 4 4 5 5 5 6 6 8 8
2.5
H 5.1 6 7 82 10 10.8 11.5 13.2 14 17.2 18.4
R 5 5 6 6 6 8 8 8 8 10 10
3
H 6 7 8.5 10 11.2 13.9 14.9 15.7 16.8 20 21.2
R 6 6 6 8 8 10 10 10 10 10 10
4
H 6.8 8 8.9 11.7 13.2 15.9 17 18.1 19.6 20.7 22
e— Material thickness
s— Depth of bottom swaging
H— Length of bottom swaging intermediate zone
R— Bottom swaging fillet radius
3 Special Case (see detail B and C in Fig.1)
Fig.1（B, C）
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3.1 Bottom swaging plate bent section parts

— Bottom swaging of plate bent parts under annealing or quenching treatment condition
should be carried out in cold or hot condition.
3.1.1 The first case (see detail B in Fig.1)
— Thickness of mating parts is e and e′.
• For e and e′ with thickness of not greater than 0.6mm，no bottom swaging is required
to be made.
• The first rivet should be positioned at a place where is 12mm from edge of lap
member
3.1.2 The second case (see detail C in Fig.1)
— The e and e′ with thickness of greater than 0.6mm
• The length of bottom swaging intermediate zone A is equal to 6 e or 6 e′，which is a
standard bottom swaging.
• The length of bottom swaging intermediate zone A is equal to 4 e or 4 e′，which is an
acceptable bottom swaging.
3.1.3 The third case (see detail D in Fig.2)
Fig. 2 (D)
— If length P′ is equal to or lower than P，then bottom swaging must made to straight
bottom swaging.
• The length of bottom swaging intermediate zone A is equal to 6 e or 6 e′，which is a
standard bottom swaging.
• The length of bottom swaging intermediate zone A is equal to 4 e or 4 e′，which is an
acceptable bottom swaging.
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3.1.4 The forth case (see detail E in Fig.2)
Fig. 2(E)
— If length P′ is greater than P，then bottom swaging must made to straight bottom
swaging then use 30℃ or 60℃ slant bottom swaging so as to obtain the length P of
equal to or lower than length P.
• The length of bottom swaging intermediate zone A is equal to 6 e or 6e′，30℃ slant
bottom swaging is standard bottom swaging.
• The length of bottom swaging intermediate zone A is equal to 6 e or 6e′，60℃ slant
bottom swaging is standard bottom swaging.
• The length of bottom swaging intermediate zone A is equal to 4 e or 4 e′，30℃ slant
bottom swaging is an acceptable bottom swaging.
• The length of bottom swaging intermediate zone A is equal to 4 e or 4 e′，60℃ slant
bottom swaging is an acceptable bottom swaging.
Note:
— If e and e′ are not equal in thickness，for the length of bottom swaging
intermediate zone，and generally, the thicker material shall be taken as a base
number.
— For the part of which the bottom swaging is formed in the quenching period，and the
length exceeds 300mm，A must be equal to 6 e or 6 e′.
— Very small spacing of continuous bottom swaging on the same part should be
avoided.
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BEND FORMING
1 Bending of Thin Metal sheet

Try as much as possible to use standard bending fillet radius. The special fillet radius can
only be used in a special case. For the part with bending length of exceeding 2m，the “N” or
“S” value of thicker plate that is nearby should selected. (All the values in the round
brackets are only used in condition that the bending length exceeds 2m).
2 Table for Determination of Fillet Radius Size According to Thickness of Metal Sheet
(see detail A in Fig.1)
2.1 Cold bending of thin steel sheet
Tensile Thickness e
strength
TS 0.5 0.6 0.8 1 1.2 1.25 1.5 1.6 2 2.5 3
Material (MPa) Radius
Bending
status
N 1.6 1.6 1.6 1.6 1.6 1.6 2 2.5 3(4)

18A 410 S 0.5 0.6 0.8 1 1.2
15CrMn 980 N 1.6 2 2.5 3 4 6 8 10

(12)
MoVA Annealing N 1 1.2 1.6 2 2.4 2.5 3 3.2 4 5 6
25CrMo N 1.6 1.6 1.6 2 2.5 3 4 5 6(8)
A 670 S 1 1.2
25CrMo 880 N 1.6 2 2.5 3 4 6 8 10

(12)
A Annealing N 0.8 0.9 1.2 1.5 1.8 2 2.3 2.4 3 3.8 4.5
00Cr19 N 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.8 2 2.5 3(4)
Ni11 490 S 0.5 0.6 0.8 1 12
1Cr18N Cold N 1.6 2 2.5 3 4 6 8 10

i11T1 working (12)
Annealing N
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The values given in the round brackets are all used for bending length of greater than 2m.
N- Standard bending fillet radius
S- Special bending fillet radius
e- Material thickness in mm
2.2 Bending of titanium and titanium alloy sheet
Forming Bending Curvature Thickness e

Material
method status radius 0.5 0.6 0.8 1 1.2 1.5 1.6 2 2.5 3
135 Cold N 1.3 1.5 2 2.5 3 4.5 4.8 6 7.5 9
N 1.5 1.8 2.4 3 3.6 6 6.4 8 10 12

T40 Hot N 1 1.2 1.6 2 2.4 4.5 4.8 6 7.5 9
Cold Annealing N 2 2.4 3.2 4 4.8 7.5 8 10 12.5 15

T60 Hot N 1 1.2 1.6 2 2.4 4.5 4.8 6 7.5 9
Cold N 1.3 1.5 2 2.5 3 6 6.4 8 10 12

TU2 Hot N 1 1.2 1.6 2 2.4 4.5 4.8 6 7.5 9
T-A6V Cold N 4 4.8 6.4 8 9.6 12 12.8 16 20 24
When titanium alloy is forming，it is particularly sensitive to defects of material surface，

so the sheet surface must be free from scratches，even minor scratches are not allowed
too.
2.3 Cold bending of aluminum alloy sheet
Bending Bend Thickness
Material
status radius 0.5 0.6 0.8 1 1.2 1.6 2 2.5 3
5086and 0or H111 N 1.6 1.6 1.6 1.6 1.6 1.6 2 2.5 3()
1050A Annealing S 0.5 0.6 0.8 1 1.2
2017A Annealing S 0.6 0.8 1 1.6 2 2.5 3 4 5(6)
PL T3 B B
N 1.6 1.6 1.6 2 2.5 4 5 8 1012
S 1 1.2
Annealing S 0.6 0.8 1 1.6 2 3 4 5 6(8)
2040and W within N 1.6 1.6 1.6 2 2.5 4 5 6 1012
quenching aging S 1 1.2
2024PL period
T3 B B N 1.6 1.6 2.5 4 5 6
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Bending Bend
Material Thickness
status radius
1.6 1.6 1.6 2.5 2.5 5
Annealing S 0.8 0.8 1 1.6 2 3 4 5 6(8)
W within N 1.6 1.6 1.6 2 2.5 4 5 8 1012
7075PL quenching
aging S 1 1.2
period
T6 B B N 1.6 1.6 2.5 4 5 6
H11 N 0.5 0.5 1 3
LD2
B B
Annealing
T4(2)
B B N 0.5 1 2 4.5
N 1.6 1.6 2 2.5 3 4 5 8 10
2618A H28 S 1 1.2 1.6 2 2.5 3 4 5 6
The values given in the round brackets are used for bending length of greater than 2m
It is recommended not to bend thin sheet made parts under the quenching condition.
However, due to a special reason，the bending must be made under the quenching
condition，then，when material thickness is not greater than 1.4 mm，minimum bending
fillet radius must be equal to or greater than the material thickness.
Under T status, when bending angle is 70℃, use that minimum bending fillet radius of
cold bending is equal to 2 e，at this moment 0.5<e<3.
N- Standard bending fillet radius
S- Special bending fillet radius
3 Special Cases (see detail A, B, C, D，E in Fig.1)
3.1 Developing material length calculation
3.1.1 The first case，bending angle α＝90°，(see detail B in Fig.1)
π e
V＝2(R+e)- (R+ ) L＝A+B-V
2 3
L Total length of developed material of bending part
V- Shrinkage ratio
Z- Neutral layer
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3.1.1.1 The selected V value when α＝90°
Plate Bending Fillet Radius R

Thickness
0.5 0.6 0.8 1 1.2 1.6 2 2.5 3 4 5 6 8 10 12
e″
0.5 0.9 1 1.2 1.4 1.6
0.6 1.1 1.2 1.4 1.6 1.9 2
0.8 1.5 1.6 1.9 2.2 2.5
1 1.9 2.2 2.3 2.8 3.2
1.2 2.3 2.4 2.6 2.8 3.9
1.25 2.4 2.5 2.9 3.6
1.5 2.9 3.5 4.8
1.6 3 3.4 3.7 4.1 4.9
2 3.8 4.2 4.7 5.1 6.4
2.5 4.8 5.4 5.9 72 8 8.9
3 5.7 6.2 6.6 7 7.9 8.7 9.6
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Fig. 1
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3.1.2 The second case：α<90° (see detail C in Fig.1)

π e
L＝A+B-2(R+e)+ [R+ (180°-α)］
180° 3
3.1.3 The third case: 90°<α≤150° (see detail D in Fig.1)
а π e
L＝A+B-2(R+e)tg［180°- ］+ (R+ )(180°-α)
2 180° 2
3.1.4 The forth case：150°<α<180° (see detail E in Fig.1)
L＝A+B L＝A+B-V
All the above cases，developed length L should take bigger integral quantity nearby in
mm.
3.2 Take an example for calculation of developed length of bending part (see detail F in
Fig.1)
Plate thickness e＝1
Sum of surface
15+52+36+15 118mm
length
R＝3
90° For coefficient of V, see Table 3.1.1.1 -2.8mm
E＝1
Shrinkage
ratio π 1
45° —2(3+1)+ (3+ )(180°-45°) -0.15mm
180° 3
135° π
135° —2(3+1)tg[180°- ]+ (180°-135°) -0.55mm
2 180°
Calculated quantity··························· 114.5mm

Total length of developed material：
Regulated quantity ······························ 115mm
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PIPE BEND FORMING
1 General
The minimum length of straightaway between two bends (see Fig.1)
Fig. 1
— For the standard value of length P, refer to Section 1.4.

— Length L of straightaway at tube end should be selected according to equipment
condition，and convenience for pipe connection and installation/removal of bushing
should be taken in to consideration.
— It is recommended the L is equal to or greater than P. (Refer to Table 1)
2 General Rules on Bending - Table 2
It is recommended to use following bending radius
• Standard bending radius： 5D
• Acceptable bending radius：3D
— In case there are many bends on the same pipe，then the same bending radius should be
used.
— It is prohibited to repeatedly bend pipe using hands.
— Tolerance of pipe wall thickness：It shall not exceed 3％ of rated thickness of the pipe.
Bending angle α should be within the range of equal to or lower than 120°，bending angle of
greater than 180°(U type) is prohibited.
—Number of bends on the same pipe should be limited，projected length of pipe should be
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selected as much as possible as per diameter and material，and it should not exceed the
specified maximum length (refer to Table 2)
— To set two equipment in opposite positions should be avoided and a separate stub tube
shall be used to directly connect them.
3 General Rules on Installation of Pipeline
— The distance between neighboring two pipes ：
• The distance between external pipe connections should be equal to or greater than 4mm，
• The distance between pipe connections must ensure tools can be used for installation and
removal .
•The distance to between pipes must be equal to or greater than 6mm.
• When a pipe is laid around equipment and instruments，structure component or along wall
panel，pipe and its clearance must be equal to or greater than 6mm.
• When pipe is near movable component，the distance form the pipe to the movable end of
this component must be equal to or greater than 10mm.
4 Selection of Elbow Size
Metric Series British Series Table 1
Outer
Min
diameter Bending radius Min Outer diameter Bending radius
straightaway
of pipe straightaway of pipe
N EX P D N EX
D R＝5D R＝3D R＝5D R＝3D P
4 20 12 25 3/16 4.76 24 15 25
6 32 18 25 1/4 6.35 32 18 25
8 40 25 25 5/16 7.93 40 25 25
10 50 32 25 3/8 9.52 50 32 25
12 63 36 36 1/2 12.7 63 40 40
14 70 45 40 5/8 15.87 80 50 50
16 80 50 50 3/4 19.05 100 63 63
18 90 55 55 7/8 22.22 112 67 112
20 100 63 63 1 25.4 125 80 125
25 125 75 125 1.1/1 31.75 160 100 160
32 160 100 160 1.3/8 34.92 175 105 175
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Outer Bending radius Outer Bending radius

Min. Min.
diameter diameter of
straightaway straightaway
of pipe N EX Pipe N EX
P P
D R=5D R=3D D R=5D R=3D
40 200 125 200 1.1/2 38.10 191 115 190
50 250 150 250 1.3/4 44.45 222 134 220
2 50.8 254 153 250
3 76.2 380 225 380
3.1/2 88.9 450 270 450
N- Standard bending radius

EX- Acceptable bending radius
D- Pipe outer diameter.
5 Selection of Bending Standard, as per pipe diameter and material
Table 2
Outer Diameter
Aluminum alloy Stainless Steel
D
Max. length Max. number of Max. length Max. number of
mm Inches
(m) bends (m) bends
4 3/16 1 10 1 10
6 1/4 2 12 2.5 12
8 5/16 2 12 2.5 12
10 3/8 2 10 2.5 20
12 1/2 2.5 8 3 10
14 - 3 10 3.5 10
16 5/8 3 10 3.5 10
18 - 4 10 4 10
20 3/4 4 10 4 10
25 1 4 10 4.5 10
32 1.1/4 3 6 3 4
40 1.1/2 2 3 2 2
- 1.3/4 2 2 2 2
50 2 2 2 2 2
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FORMING OF LIGHTENING HOLE

AND REINFORCING CENTER-DOT
1 Lightening Hole
1.1 General
The advantages of lightening hole are as follows：
— Play a reinforcing role
• It is not easy to produce cracks and corrosive brittle flange.
• With lightening hole stamped, the metal sheet will not produce deformation.
1.2 Table for geometrical dimensions of metal sheet lightening hole (see Fig.1)
Fig. 1
This Table is applicable to non-ferrous metal sheet of 0.5~2mm in thickness and steel
sheet of 0.3~1mm in thickness.
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D A± B C E Lightened Weight of Each Hole (g)

R r
±1 0.5 0.5 Min. Max.
0.5 0.6 0.8 1 1.2 1.6 2
15 21 45 34.5 15 4 2.5 0.2 0.24 0.4 0.5 0.6 0.8 0.9
20 30 62 43 15 5 4 0.4 0.5 0.7 0.8 1.05 1.4. 1.7
30 40 72 48 15 5 4 0.9 1.1 1.4 1.8 2.1 2.8 3.5
40 50 82 53 15 5 4 1.6 1.9 2.5 3.2 3.8 5.1 6.3
50 60 92 58 15 5 4 2.5 4 4 5 6 8.1 10
60 70 102 63 15 5 4 3.7 4.4 6 7.5 9 12 14.8
70 80 112 68 15 5 4 5 6 8 10 12.5 16.2 20
80 90 122 73 15 5 4 8.5 10.2 13.6 17 20.2 27 34
100 110 142 83 15 5 4 10.6 12.7 17 21 25.4 34 42
120 130 170 97 17 6.5 4.5 27 34 41 55 69
140 150 190 107 17 6.5 4.5 32 40 48 64 80
160 170 210 117 17 6.5 4.5 42 53 64 84 106
180 190 230 127 17 6.5 4.5 67 80 108 135
200 210 250 137 17 6.5 4.5 83 100 134 167
Form a flange before punching hole.
2 Reinforcing Groove
2.1 General
Reinforcing groove is formed by mechanical press machine.
Fig. 2
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Fig. 3
2.1.1 Table for geometrical dimensions of reinforcing groove
Material Material
Min
thickness L r r R h thickness
A
e e
0.4-0.8 12.5 2.3 5.7 40 3
0.6-1.2 19.4 3.7 8 45 5 0.4-2 12

2.5 16
1-2 28.7 6 10 50 9
1. 6-2.5 36.3 8.5 13 55 10
2.1.2 Recommended reinforcing groove operation value (no shadow area is to be used)
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With 10
With 10 With 10 With 10
L 60 as unit
as unit as unit as unit
40 50
L 70 400 and
80~200 210~300 310~390
above
10 ////////////// /////////// ///////////
15 ////// /////////// ///////////
20 ////// ////// ///////////
25 ////// ////// //////
3 Reinforcing Center-Dot
3.1 General
— Reinforcing center-dot shall be formed rubber press.
— It is applicable to light alloy sheet of 0.5~2mm in thickness or 0.3~1mm soft steel plate
in thickness.
3.2 Table for geometrical dimensions of reinforcing center-dot to be selected according to
material thickness (see Fig.3)
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D±0.5
30 40 50 60 70 80 90 100 120 140 160 180 200
B±0.5 62 72 82 92 102 112 122 132 160 180 200 220 240
H±0.5 3 3 3 3 3 3 3 3 4 4 4 4 4
R 11 11 11 11 11 11 11 11 14 14 14 14 14
3.3 Size of reinforcing center-dot

Material Material
thickness
Min. Approximation thickness H1 +0.05
B B
L1
B B R1
B B
C r e
e
0.5 5 2
0.5-1.2 3 16 11
0.6 5 2.1
0.8 6 2.3
1 8 2.5
1-2 4 20 14
1.2 8 2.7
1.6 10 4.1
1.6-2 4 30 25
2 12 4.5
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FORMING
1 Forming of Nylon 11 Polyamide Fiber Pipe

1.1 General characteristics of nylon 11 polyamide fiber pipe；
— Nylon 11 polyamide fiber is not influenced by chemical and electrolytic corrosion
(atmospheric electric current)，thus ensure pipes to have a longer service life.
— Generally ， the nylon 11 polyamide fiber is very capable of resisting alkali,
non-chloride solvent, oil, grease, mineral oil base product and organic acid；
— The nylon 11 polyamide fiber should not be used together with following products：
Concentrated mineral acid - ice-like acetic acid - phenol - cresol - trichloroethylene -
chlorine - chloride solvent - acetone - ketone.
Note: The diluted mineral acid resistant performance of Nylon 11 polyamide fiber pipe
depends on the property.
2 Machine-Shaping Process of Nylon 11 Polyamide Fiber Pipe，
2.1 General
—Tools used for saw cutting，thread tapping，drilling，milling，turning and grinding
operation are similar to the tools which are used for light metal；
— For machine-shaping (bending，sleeving, gluing，welding and connection)，various
kinds of processing procedures can be used，of which, only the most universal
processing procedures will be specified. These operations should be carried out
according to procedure described below.
— The formers should made of material such as duralumin or wood，and should have
enough rigidity, so as to fix various kinds of formed pipes，until they are completely
cooled.
2.2 Machine-shaped pipe
—Nylon 11 polyamide fiber pipe machine-shaping should be conducted in one step with
temperature of 160~180℃，
—Gradually and regularly heat only the parts to be machine-shaped，so as to prevent any
overheating；
— Use one oil tank or one oven (use controlled gas) for heating, so that it can be heated
uniformly and properly；
— Cooling should be carried out by soaking it in water，or using the method of water
washing，and if component is too big in volume,，even can be performed quickly using
one sponge，and pipe is still on the tool while being cooled.
2.3 Bending pipes (Fig.1-detail A)
2.3.1 General
— Bending should be carried out using a hot working procedure in the appropriate
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template；
— Minimum bending radius(R) is 5 times as large as pipe diameter ；however，if there
is requirement for assembling，it can be reduced to 3 times as large as pipe
diameter，but it is difficult in operation；
— A recess that is in compliance with outside diameter of all pipe areas to be bent
should be used to guide the pipe. Maintain the section material (2), which is not
required to be bent, in a proper position，and a cushion block is required;
— Bending angle should be increased by 10°，so as to compensate the shrinkage of
nylon 11 polyamide fiber (Item a-Fig.1-detail A).
2.3.2 Operation procedure
2.3.2.1 Operating procedure for maximum diameter of 12mm and bending radius of 5
times not smaller than pipe diameter
a. Insert a rubber or core of which the outside diameter is equal to internal diameter
of bent pipe into Nylon 11 polyamide fiber pipe. Pulling method should be used
for assembling the core instead of pushing method.
b. Put an assembly in oven, and last for 10min under temperature 160℃.
c. Use one metal bending template：
• Carry out bending，then clamp it；
• Return the assembly back to the oven under temperature 160℃ for 30min；
• Quickly soak the assembly into water，until it is completely cooled；
• Remove the rubber core.
d. Use one wood bending template：
•·Carry out bending，then clamp it；
• Put the assembly in a chill box，keep it for 1hour.
2.3.2.2 Operating procedure for minimum diameter of 12mm and bending radius of 5
times not smaller than pipe diameter
a. Quickly and repeatedly use a wide flame to heating pipe in the whole length
scope，making the heat quantity distributed to 使 the entire pipe wall thickness.
b. Put the pipe on template for bending and clamping.
c. Quickly keep on spraying cold water on the pipe, until the assembly is
completely cooled.
Note: This procedure can be used for either metal template or for wooden
template.
2.3.2.3 Machine-shaping procedure for pipes with diameter of greater than 20mm
These pipes must be always fully filled with sand heated to 90℃，and then close
two ends，and it can also be fit with one sliding matching rubber core or coil spring
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to prevent pipe from being bent to a sharp angle.

2.4 Nylon 11 polyamide fiber pipe of sleeve (Fig.1-detail B)
2.4.1 Operating steps
2.4.1.1 Assembling procedure for nylon 11 polyamide fiber pipe with maximum diameter
of 12mm.
a. Machine one external groove on the male pipe, and one internal groove on the
female pipe.
b. On the inside of the male pipe of one wooden mandrill device，use a cutting
nippers to clamp the assembly，pay a special attention to carefully mark the
outside of nylon 11 polyamide fiber pipe.
c. On the male pipe (2) and female pipe (1) ，use a pencil to mark the length to be
fit with sleeve，that is：about 2 times larger than pipe diameter plus 5mm outside
the pipe.
d. Apply oil to the length of male pipe to be fit with sleeve.
e. Use hot gas flame or oil tank (160~180℃) to soften the portion of male pipe to
be fit with sleeve.
Note: Soak the pipe into oil for several times, but the total time should not
exceed15s. When the pipe becomes transparent，check the extent has been
softened，then install the sleeve.
f. Quickly assembling the female pipe, and there must be no torsion in the range
from the male pipe to pencil mark scope.
g. Use one water spray pipe or one wet sponge to cool the sleeve，and then separate
two pipes to be bonded.
h. Remove the wooden mandrill.
2.4.1.2 Assembling the pipe connector and nylon 11 polyamide fiber pipe (Fig.1-detail C).
— The sleeve of metal pipe connector provided with splined male end fitting is
very simple.
First of all, soften pipe (2) in the oil tank or water under temperature 100℃, and
then press it into the end fitting (1). After that the assembly should equipped with
one genera purpose (corrosion proof) clamping device (3), which his made of
stainless steel.
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Fig. 1
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2.5 Flaring nylon 11 polyamide fiber pipe (Fig.1-detail D)

Use the steps the same as that of fitting a sleeve：
a. Soak the nylon 11 polyamide fiber pipe in an oil tank with temperature of 180℃ by
flared depth within the range of specified length，soften its end , then fit pipe (1) on the
tool (2), which is pre-applied with grease (general grease Z9-15) , with a required tape.
b. Soak the assembly into cold water for cooling，then，remove the tool.
2.6 Bond the nylon 11 polyamide fiber pipe
2.6.1 General
RILSAN 与 RILSAN bonding can be carried out on the unit which is provided with a
matching surface and small clearance like sleeve.
2.6.2 Bonding of RILSAN to RIDSAN (Nylon 11 polyamide fiber) (Fig.2-detail B)
a. Wipe two segments clean to be assembled.
b. Rough the bonding area using emery paper No.320.
c. Use trichloroethylene to thoroughly clean grease from surfaces of both male and
female zone.
d. Use a brush to apply a coat of thin RILSANOL21 bonding agent to the specified
length of male section and female section.
e. Dry it for 3~5min.
f. Fit one section material on another without turning over.
g. If possible, it should be kept in the environmental temperature or in oven of
temperature 70~80℃ under light pressure for 24~36h，so as to speed up drying.
Under this condition, RISANOL33bonding agent should be used.
Note: Never apply too much bonding agent：This bonding agent is used to bond two
components，and it can not be used to fill clearance .
This bonding agent is a kind of compound that is easily corroded，and it should be
used in a room with good ventilation. Operator should put on gloves. These bonding
agents be substituted by ARALDITE101 (curing time ：在 20℃，24~48h, refer to
20-06-02-101 operating steps in this manual ).
2.6.3 Various types of bonding used for RILSAN pipes
— Detail a：Assembly fit with sleeve and bond；
— Detail b：Flared and bonded assembly；
— Detail c：Butt jointed assembly with externally bonded sleeve；
— Detail d：Bonded butt jointed assembly：Bonding agent, weld bead.
2.6.4 Bonding metal components on RILSAN pipe
It is necessary to use ARALDITE AY101(Refer to 20-02-06-101 surface
preprocessing，application of Araldite and curing time of this manual ).
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2.7 Welding RILSAN pipe

Welding operation should be done very carefully.
2.7.1 Equipment required
— Hot gas welding torch (gases of using flame for heating：acetylene, propane, butane,
or use resistance heating)；
— Oilless and dust-free compressed air；
— RILSAN welding rod ：2.5mm is used for pipe with maximum diameter of
50mm.3mm diameter is used for pipe diameter of above 50mm.
— Agent used for RILSAN welding (seller：SteORGANICO).
2.7.2 Operating steps (Fig.2-detail B)
— Remove the surface grease of area to be welded using trichloroethylene，and before
the welding operation, wet these area for a while using the agent.
Fig. 2
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— Adjust hot gas temperature to 200-220℃；

— Bevel cut the end of welding rod (14)；
— In the area to be bevel cut welded，slightly heat the pipe, and put the bevel cut end of
welding rod on heating position (12) without compression；
— Upon feeling adhesion of welding rod，use the forward movement (13) and up
down movement (11) to supply hot gas；
— Four courses of welding shall be made to obtain a satisfactory welding (items 1, 2,
3，4 in Fig. )；
—Completely cool the welded assembly before using.
Note: A weld formed section should be avoided, because use of weld torch will cause
the pipe return to its original state. In case the section has already been formed, then
a weld iron should be used (on tin soldering flux operation).
2.8 Assembling on aircraft
2.8.1 General
RILSAN pipe shall be fixed on a structure using plastic clip (nylon clip shaped HP)，
so as ensure there is no any movement, and at the same time to prevent over-tightening.
If possible，spacing between clips should be 20 times lower than the outside diameter of
pipe.
When the assembling is conducted on aircraft，the preventive measures should be taken.
Protect pipes against abrasion with points and edges of holes or components assembled
or to be assembled，and prevent pipe from being crushed and bending with force by
hands.
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PITCH AND EDGE DISTANCE AND COUNTERSUNK HOLE OF RIVET
1 Riveting —Pitch and Edge Distance

1.1 Selection of rivet length
— Theoretical rivet length “L” is given by formulas below：
— Metal sheet without center-dot＝riveting method C or G
L＝1.1e+1.5D
—Metal sheet without center-dot＝riveting method F
L＝1.1e+D
— Metal sheet with center-dot＝riveting method C or D
L＝1.5e+1.5D
e＝Total assembling thickness
D＝rivet diameter
These formulas are applicable to diameter 5mm rivet (including 5 mm).
Note:
— C riveting method＝shape of contour squeeze：Circular，flat.
— G riveting method＝shape of contour squeeze：Flat
— F riveting head＝ shape of contour squeeze：Countersunk 100°
1.2 Drilling of metal sheet
— Table 1—diameter of drilling is selected according to rivet diameter.
Rivet diameter 1.6 2.4 3.2 4 4.8 5.6 6.4 8 9.6
Drilling diameter 1.7 2.5 3.3 4.1 5 5.8 6.6 8.2 9.8
1.3 Marking-off and rivet pitch

1.3.1 Arrangement of rivet rows（see Fig.1)
a One raw of rivets (see detail A)
b Several rows of rivets (see detail B)
1.4 Table 2—Rivet pitch is determined according to rivet diameter
Rivet diameter (mm) 2.4 3.2 3.6 4 4.8 5.6 6.4 8 9.6
Standard operation Min. 12 13 15 16 20 23 26 32 40
condition Standard 20 25 28 30 35 40 45 50 70
(1) Min. 25 35 38 40 50 55 65 80 100
Pitch
“P” For riveting of sheets，the total thickness is equal to, Pitch is
or smaller than half of rivet diameter “D” 3.5D—4D
Operation in
sealing area For riveting of sheets，the total thickness is greater Pitch is
than half of rivet diameter “D” 4D—5D
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Note: Rivet pitch shall be selected according to the load to be transferred within the limit
given in the Table (it is better to use standard pitch (1))
1.5 Table 3—Edge distance (C) shall be maintained according to rivet type
Rivet diameter(mm) 2.4 3.2 3.6 4 4.8 5.6 6.4 8 9.6
100° countersunk head or
mushroom Monel alloy 7 8 8.5 9 11 12
Steel-titanium rivet
Edge 100° countersunk or
distance mushroom aluminum ally 5.5 7 7.5 8 95 11.5 13
rivet
G SLand LOCK 100°
(Note) rivet 10 11 13 16
Thread rivet countersunk
( connecting
bolt) Mushroom
Hi—LOCK 9 10 12 14.5
screw
and other rivets
Note: When the sheet is chamfered, 1mm shall be added to the edge distance.
1.6 Rivet arrangement on convex and bending or extruded section (see detail C in Fig.1)
Rivet diameter (mm) 2.4 3.2 3.6 4 4.8 5.6 6.4
Minimum B value Aluminum alloy 3 4 4.5 5 6 7 8

determined according to
material Monel—Titanium—Steel 4 5 5.5 6 7 8 9
Note: Check that the length of flange, crimping or press formed section material should
put the minimum size B into consideration，which is not related to the number of
rivet rows.
1.7 Determination of rivet diameter on non-parallel planes (see detail D in Fig.1)
Α (maximum value) Rivet diameter(mm)
10° 2.4—4
7°30′ 4.8—5.6
5° 6.4
2°30′ 8—9.6
2 Countersunk Hole of Rivet Head and Tail (see detail E in Fig.2)

2.1 Countersunk hole of 100°countersunk rivet
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RivetNominal
diameter
countersunk of rivet 1.6 2.4 3.2 3.6 4 4.8 5.6 6.4 8 9.6
head (mm)
Max.
100° 2.80 4.45 5.61 6.46 7.17 8.87 10.44 12.00 14.23 17.53
value
A Min.
2.65 4.30 5.45 6.30 7.00 8.70 10.30 11.85 14.00 1730
value
Countersunk
Min.
EI 0.60 1 1.20 1.40 1.60 2 2.50 2.70 3.00 4.00
value
Max.
Flat 4.55 5.71 7.27 8.97 10.54 12.10
value
A Min.
10° 4.40 5.55 7.10 8.80 10.40 11.95
value
Countersunk
Min.
round head EI 1 1.20 1.60 2.00 2.50 2.70
value
rivet
2.2 Rivet tail

2.2.1 Countersunk rivet tail
Rivet tail countersunk holes and 100°countersunk rivet heads and holes are the same.
2.2.2 NACA rivet tail (see detail F in Fig.2)
Diameter of rivet 3.2 4 4.8
A——Max. value 4.93 6.12 7.44
E——Min. value 1.20 1.40 1.80
2.2.3 Determination of rivet projected length (see detail G in Fig.2)

In order to obtain the rivet tail sizes (C-H) described in Table below，actually the given
values of all rivet projected sizes (d) shall be: d＝1.5D
Rivet diameter 1.6 2.4 3.2 3.6 4 4.8 5.6 6.4 8 9.6
Max. value 3.3 4.8 6 6.5 7.5 8.7 10 11 13.5 16
C Min. value 2.3 3.3 4.5 5 5.6 6.7 8 9 11 13.5
Max. value 1.1 1.6 2.1 2.3 2.6 3.2 3.7 4.2 5.3 6.3
H Min. value 0.6 0.8 1.1 1.2 1.3 1.6 1.9 2.1 2.6 3.2
E——Min. value 0.4 0.8 1 1.2 1.4 1.8 2.3 2.5 2.8 3.8
3 Requirements for General Inspection of Riveting

— Refer to task card 20-02-04-601 of Specification for Riveting Acceptance in this manual
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Fig. 1
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Fig. 2
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4 Specification on Pitch (P), Edge Distance (G) and Heading Size of China Made Rivets
4.1 Diameter and allowable tolerance of rivet hole
Rivet diameter 2.0 2.5 3.0 3.5 4.0 5.0 6.0 (7.0) 8.0
GB1017 5.1 6.1 (7.1) 8.1
2.1 2.6 3.1 3.6 4.1
HB0-40 5.2 6.2 (7.2) 8.2
GB1017 +0.12 +0.16 +0.2
Recommendation +0.1 +0.15 +0.2
Deviation of rivet hole
+0.2 +0.3
to be replaced
4.2 Determination of rivet pitch (P)

Positions of rivet holes will be determined according to sizes in drawings.
Rivet pitch unnoted in drawing may be calculated and selected according to the following
formulas：
P＝4d+S
Internal P：Rivet pitch
d：Rivet diameter
S：Total height of riveted parts
4.3 Determination of rivet edge distance (G)
Edge distance of rivet hole should be in compliance with provisions in drawings.
Rivet edge distance unnoted in drawing may be calculated and selected according to the
above formulas：
G＝1.5D+2
Internal G：Edge distance of rivet hole
d：Rivet diameter
4.4 Rivet tail diameter (D) and its deviation, minimum height，shift (K) relative to the center
line of rivet bar and out of roundness.
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Rivet diameter(d) 2.5 3.0 3.5 4.0 5.0 6.0 7.0 8.0
Button head
3.9 4.5 52 6.0 7．5 8.7 10.2 11.6
diameter(D)
D deviation ±0.25 ±0.3 ±0.4 ±0.5 ±0.8
Button Min. height (h
1.1 1.2 1.4 1.6 2.0 2.4 2.8 3.2
head min)
B B
Relative rivet bar Not more than 0.2, and at places where it is hard to work, not
(K) more than 0.5, and not exceed 10％
Ellipticity Within allowance limits of diameter (D)
Note: Heading height h=(0.5±0.1)d

Heading diameter D=(1.5±0.1)d d<5mm
D=(1.45±0.1)d d>5mm
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SPECIFICATION FOR RIVETING ACCEPTANCE

1 Requirements for General Inspection of Riveting
a Check if the rivet pitch and edge distance is correct .
b Before assembling parts，check if there are burrs，if rivet hole is clean, and if there are any
metal chips.
c Make sure rivet and hole is accurate so as to prevent cutting of rivet hole and head.
1.1 Allowable rivet deformation
a Allowable eccentricity (see detail A in Fig.1) may be tangential to rivet bar..
b Unsatisfactory eccentricity (see detail B in Fig.1)
c Allowable defect (see detail C in Fig.1)
Note: The difference between minimum height (h) and maximum height (H) should be
less than rivet diameter by 1/3.
That of less than 1/6 diameter is not considered as a defect.
1.2 Allowable cracks (see detail D in Fig.1)
Light crack is allowed whether depth does not exceed 1/8 of rivet diameter (b not greater
than d )，and the width e does not exceed 1/16 of rivet diameter (a is not greater than
8
d ）.
16
Note: Crack of spreading to other place exceeds the limit is not allowed.
1.3 Allowable rivet knock trace
On rivet of raised head (see detail E in Fig.1), if maximum size of rivet knock trace “P” is
h
smaller than 1/4 of rivet height (P< ）, then it is allowed.
4
Note:— Rivet knock trace on a thin metal sheet is not allowed. The thin metal sheet
means that plate of which thickness ≤0.8mm.
— The minor scratch can be removed using a polishing procedure shall not be
considered as a defect.
2 Inspection of Installation Condition of SL Rivets
2.1 Bearing surface of rivet head
There should be no gap between rivet heads and their bearing surfaces or sockets.
However, if maximum clearance is 0.1mm，and following requirements are also met，then
10% can be accepted in one raw of rivets (see detail A in Fig.2)：
— This clearance does not exceed the half of rivet bearing surface
—This defect does not appear on two continuous rivets.
— The allowable percentage of defective rivet is not in the same area
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2.2 Protruded quantity between collar and rivet shank

— The allowable protruded quantity of rivet bar relative to collar top shall be ±0.8mm
— Any doubtable protruded quantity should be inspected using maximum and minimum
gauges shown in Fig. (see detail E in Fig.2)
— When largest side of gauge is against bearing surface, and the smallest side of gauge
can not be in contact with the bearing surface, the projected quantity of rivet should be
considered in the allowable limit of acceptance.(see details F, G in Fig.2)
— Any rivets of which the protruded quantity exceeds the gauge allowable limits must be
replaced.
2.3 Cracks of flanged collar
2.3.1 Unacceptable defects
a Two typical types of acceptable cracks(1) after flanged；
— Ring cracks at the intersection of cone and cylindrical section of collar (see detail B
in Fig.2)
— Cracks on top along matrix (see detail C in Fig.2)
— It is required to pay attention to that the protective surface of flanged collar is free
from neither deep crease nor obvious tool damage caused by clincher tool.
— Minor cracks on the anodization coat will not be a reason of rejection.
b These defects cause system replacement of rivets
Remarks: As long as defect can be removed by slight grinding, the inspectors can
evade the replacement of rivets that have very small defect indication along
matrix.
Penetrant flaw detection method must be used to check these defects after their removal.
If the result of inspection by penetrant method is unsatisfactory，rivets should be
replaced.
2.3.2 Acceptable defect
a Cracks near internal diameter points on the upper surface of collar (see detail D in
Fig.2)
b Defects under following condition are acceptable：
— The only defect does not exceed 1/4 of circular length collar.
— Acceptable defective flanged collar must be located in between two defect free
collars.
— The quantity of acceptable defective flanged collars must not exceed 10％of flanged
ring number specified on assembled part.
2.4 Inspection gauge
a The flanging quality shall be checked by the gauge in Fig. (see detail E in Fig.2)
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b When the end of gauge which is positioned on the collar, is in contact with the
assembled sheet，it shall be considered as correct.
c The gauge shall be made of 1mm steel sheet according to St.CHAMOND-GRANAT
published drawing №81 SL 8100.
d The table below presents size each gauge based on Fig.2-detail E according to rivet
diameter.
Rivet
A±0.025 B±0.025 C±0.005 D±0.1 E Φ±0.1
diameter
4 6.50 4.20 8.20 3.20 20 2.50
5 8.10 5.80 10.00 4.00 22 3.00
6 9.60 7.30 11.80 4.80 24 3.50
8 11.20 8.90 15.50 6.50 28 4.50
10 13.30 11.00 18.50 8.50 30 5.00
e The “largest side” of gauge must always be against surface (see detail F in Fig.2).
f The smallest side of gauge is absolutely not allowed to be against surface (see detail G
in Fig.2).
2.5 Error of metal sheet extruded deformation caused by riveting.
2.5.1 Raised head rivet (see detail A in Fig.3)
— when 0.06 mm thick filler gauge can not be in contact with rivet bar，the allowable
clearance J＝0.4mm.
15/100mm thick filler gauge can not go between two rivets.
Note: There should be no clearance under rivet head.
2.5.2 Countersunk rivet (see detail B in Fig.3)
The allowable clearance between metal sheet in countersunk rivet are as follows：
Rivet diameter(mm) Clearance X(mm)
≤3 +0.2
3--6 +0.3
>6 +0.4
Note: It is not allowed that there is ring or eccentric clearance (J) between countersunk
rivet and countersunk hole (see detail C in Fig.3)
2.6 Allowable defect on countersunk hole of accommodating countersunk rivets.
The size of countersunk hole should be provided according to the correct rivet
coordination condition.
The maximum allowable protruded O shaped head of metal sheet surface shall be 0.15 to
0.20mm(see detail D in Fig.3)；
Maximum dishing shall be 0.03mm (see detail D in Fig.3)
Note: For the rivet head of exceeding maximum tolerance, if metal thickness variation to
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be removed is less than 0.2mm, it is allowed to be planished.

The angular tolerance of countersunk hole: 100°±30′.
2.6.1 Re-machining with a general polisher (see detail E in Fig.3)
— Cross cut edge of conic and cylindrical surface (1) can be re-machined with polisher.
The polished width should be approximately 0.2mm.
2.6.2 Inlet of countersunk hole（see detail F in Fig.3)
The outside diameter of cutting tool should be greater than maximum diameter of
countersunk hole so as prevent from being cut into cylindrical section.
The (1) shown in detail F is prohibited countersunk hole, (2) is correct countersunk
hole.
2.7 Metal sheet deformation caused by riveting
The deformation caused by expansion of rivet between metal sheets or metal chips is
prohibited (see detail G in Fig.3).
Fig. 1
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Fig. 2
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Fig. 3
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CONNECTION
1 General
Purpose of this chapter is to provide users with necessary instruction on structure repair by
riveting, welding and assembling to obtain a reliable connection.
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IDENTIFICATION OF LEFT-HANDED THREAD ASSEMBLY MARKS

1 Identification of Left-Handed Thread Assembly Mark (according to standard NF
E.27.004)
1.1 General
When thread is invisible，the direction mark should be used to indicate the thread
direction to prevent damage to left-handed thread assembly
1.2 Generally the followings should used (see detail A in Fig.1)
— Directing sign is a very shallow circular groove (2). For small diameter tube part，a
knurling (3) can be used in place of the groove.
— On a thread bar，groove (2) must be neither free from cusped edge and nor exceeding
4/10 of pitch depth
1.3 Directing signs on the flat fillister head and countersunk screw (see detail B in Fig.1)
— The directing sign is comprised of 2 saw-cutting marks (4) in parallel with groove (5)
on head. The saw-cutting mark is relatively narrow and not as deep as the groove.
1.4 Directing sign on internal hexagonal screw (see detail C in Fig.1)
Two shear marks can be substituted by a single shear mark(6), which are orthogonal to
two appropriate surfaces of internal hexagonal screw.
1.5 Substitution sign used on small screws with flat fillister head, countersunk head or hex
head (see detail D in Fig.1)
For small cylindrical countersunk or hex screw, its sign can be a small diameter
semi-spherical concave made in center of head (7).
1.6 Sign on the end fitting (see detail E in Fig.1)
This sign consists of radial groove (8) with width of 0.5mm and depth 0.5mm.
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Fig. 1
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CORRECT OPERATION FOR RIVETING OF STRUCTURAL PARTS
1 Connection of Structure Parts Using Riveting Method

1.1 General
The purpose of this operation is to provide a correct connection of structural part.
1.2 Cross connection of one structural part with another structural part
1.2.1 Non-rigid connection (see detail A in Fig.1)
Minimum clearance (J)＝0.5mm between structural parts must be executed.
1.2.2 Rigid connection (see detail B in Fig.1)
minimum clearance (J) between structural parts＝0.2mm .
1.3 Butt joint
1.3.1 Butt joint of non-rigid support (see detail C in Fig.1)
Minimum clearance (J)＝0.5mm.
1.3.2 Butt joint of rigid support（see detail D in Fig.1)
Minimum clearance (J)＝0.2mm
1.4 Tenon joint (see detail E in Fig.1)
In case a clearance between 0.1 and 1mm exists at tenon joint，a shim washer can be
added.
If it is 1mm and more，replace the part.
1.5 Connection inside section material or bent section material
1.5.1 General situation (see detail A in Fig. 2)
Clearance (J)＝1mm±1
L>1.7d：It is used only in the end rivet or screw when one butt joint is used.
L is >2d all the time：It is used under the case of one raw of rivets.
J＝Distance to be maintained with tangential point
L＝Edge distance shall be maintained between center of rivet or screw and sheet end to
be assembled to the section material.
d＝Diameter of rivet or screw
1.5.2 Special case（see details B-C-D in Fig.2)
—Connection inside a section material
— All are narrow convex edge connection
The edges should be cavetto, chamfered or shear-cut into saw-tooth form.
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Detail B Detail C Detail D
J＞0.5mm J＞0.5mm For connection with a thick

e＝0.5±0.5 Connection flanged sheet and plate，the edge of thick plate
Connection of beveled sheet section material should be cavetto .
and section material
1.6 Locating before riveting (see detail E in Fig.2)

— ForA-U4G(2017A) and A-U4G1(2024) sheets with maximum thickness of 1.6mm，
when sheet(1) is to be located prior to riveting，it is allowed to have a 3/10mm
clearance existed in the condition free from stress.
— For A-Z5GU (7075) sheet (1) with maximum thickness of 1.6mm, its clearance which
is present in the condition free from stress should be reduced to 15/100mm.
When the clearance exceeds 3/10mm and maximum clearance reaches 2mm，and the
maximum length is 10％developed length of assembled part，an additional A-U4G(2024)
wedge gasket (2) can be provided.
Fig. 1
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Fig. 2
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WELDING
1 Use of Fusion Welding Process and Brazing Process for Connection of Steel,
Aluminum and Titanium Structural Parts
AIR 9111 Test and Acceptance Specifications for Welding Aluminum Alloy Workpiece
with Connector or Joint
AIR 9117 Steel Welding, Welding Rod Acceptance Specifications
AIR 9118 Test Condition for Fusion Welded Steel Bars
SY-51 Operating Instruction Manual of Structure Steel and Stainless Steel Fusion Welding
SY -53 Operating Instruction Manual of Aluminum Alloy Fusion Welding
SY -55 Operating Instruction Manual for Braze Welding
SY -56 Instruction Manual for Preparation of YJ3 Hard Brazing Flux
SY -129 Operating Instruction Manual for Storage, Handling and Check of Welding Material
SY Z9-11 Operating Instruction Manual of 5086 Aluminum Alloy Argon Arc Welding
Z9/22201-92 15CrMnMoVA Steel Tungsten Electrode Argon Arc Welding Procedure
1.1 General
Fusion welding of any steel, aluminum alloy and titanium components should be in
compliance with the relevant requirements specified in this document.
The processing method is as follows：
— oxyacetylene welding (OA)；
— Use refractory electrode to perform the inert gas protection arc welding (TIG)；
— Use coated metal to perform the arc welding (E)；
— Soldering and hard brazing.
1.2 Type of component
Use the following methods to obtain welded assemblies：
— Steel and titanium fusion welding；
— Light alloy fusion welding, soldering and hard brazing.
— It is divided into two types according to the functions they undertake:
Type A: The weldments that are not directly related to strength，safety or operation of
aircraft, but only to supplementary functions, such as pressed parts of paddle,
cowling, elbow, air duct support, and pressed parts of air inlet duct or exhaust
duct, cable or pipe clamps.
Type B: The weldments that are directly related to strength，safety or operation of
aircraft，provide very important functions, such as longeron，wing spar,
structural skin panel，landing gear, engine mount, wing spar connecting lug, all
welded structure area - fuel system，control device surface mounting joint，and
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balance weight support.

Manufacture of B type parts is rates as two classes：
Class B1: The safe connectors that are not directly related to parts, such as axle bushing.
Class B2: The connectors that are not directly related to the correct states of parts in
operation, such as strength and air tightness.
1.3 Fusion welding method
Metalli
Heating Remar
Description Symbol Weldable Metal ** c* Flux
source ks
Filler
Low carbon steel
Inert gas Arc of 15CrMnMoVA(15CDV6)
protective T1G isolating the Steel 30CrMnSiA Yes No Inert
arc welding air between GH3030 gas
of infusible workpiece Corrosion Z2CN18-10 protect
electrode and welding resistant OOCr19Ni11 ion on
called rod and steel 1Cr18Ni9Ti Yes No the
“non-consu surrounding 1Cr18Ni9 reverse
mable through an L1—L6 side
electrode” inert gas LF3 LF5 LF6 LF21
Aluminum 5086 Yes No
alloy LD2
LY12
* For packing metal and flux，refer to Para. 1.7.

** Only the metals of the same material can be welded together.
In case welding is carried out on a flanged edge，the melting of the edge will substitute for
filling metal .
Protect the back of joint through by inert gas is required for 15CDV6(15CrMnMoVA) steel，
corrosion resistant steel and titanium.
In some cases，for low carbon steel ，aluminum and magnesium alloy are also necessary.
1.4 fusion welding method 的selection
Weldable metal Symbol Remarks
Deformation is big，mechanical performance low，and it is
OA easily overheated
Steel TIG Mechanical performance is fine，deformation light
It can not be used for below 2 mm，and it is widely when
thickness is greater than 4mm.
E Mechanical performance is fine，deformation small
It is often used for butt joint part with thickness less than
OA
Aluminum and 1mm，and it is required for leveling after welded
magnesium alloy Method in common use, no cleaning is required after welded，
TIG with minor deformation
Titanium and As per Para. 1.5.
titanium alloy
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1.4.1 Design of fusion welded part (Fig.1)

1.4.1.1 General
In addition to that regulations of design of fusion welded part below to be observed,
as following regulations should also be provided：
— Position of welded seam. The welding torch neck，welding rod and metal should
be able to reach the welding position，to ensure a normal welding；
• Parts drawing A： Minimum angle should be ensured
• Parts drawing B：Incorrect direction
• Parts drawing C：Correct direction
• Parts drawing D：Principle for butt joint welded seam.
— Two welded seam should not be intersected, particularly thick parts. Fillet
welded seam and the reverse side welding of part with thickness less than 2mm
should be avoided；
— Too thick fillet welded seam shall be avoided；
— Try as much as possible to incline the welded seam according to the action line
of stress，so as to prevent welding defects concentrated in the same segment；
— This procedure can not be used for pipe connection，it is better to use a flat butt
joint or flat butt joint with setting-up piece (see item11, Para.1.4.1.2 )；
— Try as much as possible to weld part with the same thickness；
— if part strength and operation is allowed, then the interrupted welded seam can
be used；
— Welding of too many pipes got together should be avoided，for it may cause
welding to become more difficult and，and lead to overlapping and thick
welding coat，which is a potential cause for cracks and deformation.
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Fig. 1
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1.4.1.2 Form of welding
Joint or Joint or
Thickness
connection not connection Welding Remarks
(mm)
recommended recommended
OA(1) e<4 For aluminum and
1 or E 4≤e≤8 magnesium alloy, refer to
or TIG e>8 Para. 1.4.
TIG(2)OA(3)
E For thick aluminum and

2 or e>2 magnesium alloy, TIG
process shall be used：
TIG(2) e≥12
OA(3) There is no filler metal ：r
3 shall be as small as possible
or E＝0.5—1
TIG
OA or There is tapered thick metal
4 E plate in one or two
positions，when >1.5；
or L=4(e-e)
TIG L＝2e
e2
≤e1≤e2
5 OA 2 For corrosion resistant steel，
B B
E e3 titanium and magnesium

≤e1≤e2 alloy，TIG process shall be
3
B B B B
TIG(4) used
L≥e2 B B Influence of shrinkage
e2 deformation：
OA e2
e1≤
2 e1≤3：There is no welded
B B
seam of welding at the

back
6 E E＝0.5—1 Fillet welded seam and the
or reverse side welded seam
≥12：In fillet welding in type
e2 B part only joints a and b
3 ≤e1≤e2 should be used.
TIG B B B B
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Joint or Joint or
Thickness
connection not connection Welding Remarks
(mm)
OA Tapped pipe and
or fuel tank
TIG
E For sheet of e≤2 ：in case

there is no angle or filler
or metal：h′=1.5e for sheet with
e>2：in case there is angle，but
TIG
no filler metal, h＝e
TIG 1≤e≤2
It is set for steel, aluminum

alloy and magnesium alloy
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Joint or Joint or
connection not connection Welding Thickness
(mm) Remarks
OA(7) Electric spot welding is used
for strength welding, and
fusion welding is used for
or tightness welding.
Weld the protruded connector
of aluminum, magnesium
alloy and stainless steel slots.
R=3～4e
TIG For stainless steel, only TIG
10 method is used.
OA if e＝1，a＝0.2
e
or J＝ 2
11 TIG if e＝2—3，a＝0.5
1.5 Requirement for titanium welding

1.5.1 Welding method
Titanium can only use tungsten electrode inert gas protective welding ( code TIG)，use
or not use filler metal fusion welding.
1.5.2 Chilling and locating
At the time of welding, weldment shall be located using the bars installed on both sides
of the welded seam and chilled by bars installed on both sides of the weldment.
In order to limit heating deformation，fix the weldment by fastening the support rod on
the chill bar.
Under the various welding conditions，even after welding completed, both sides of the
joint should be accessible，so as to provide possible welding by both sides.
1.5.3 Simple welded connection (Fig.1)
In all possible areas，it is preferable to use the butt joint welding, because this king of
joint is easily done，and it can bear higher load.
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— Detail E：butt joint welding ；

— Detail F：Simple welded connection；
— Detail G：connecting the permanent joint，mounting base, etc.；
Notes in details：
① Chill bar
② Fixed support bars
③ Sheet to be welded (titanium metal )
④ Inert gas supply source.
1.5.4 Use welding method to connect the permanent joint，mounting base, etc (Fig.1-detailC).
The welding is related to the butt joint welding.
16 Metal sheet and welded seam dimensions
1 In case of both sides welding In case of one side welding
2 Minimum possibility
The thinnest part X Y Z h j b

0.5—1 3
1.2—1.6 4
2 1 4.5
3 1 5 1 1
4 and 5 2 0 5 2 1
6 2 1 6 2
8 2 1 8 2
10 2 2 4 10 2
12 2 2 5 12 2
In case of both sides welding In case of one side welding Minimum possibility
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1.7 Filler metal

1.7.1 Steel
Welding
Matrix Metal Filler Metal Remarks
Procedure
20 H08A
15CrMnMoVA(15CDV6) H15CrMnMoVA(15CDV6)
30CrMnSiA H18CrMoA
22CN18-10
B B Z2CN18-10 or HOOCr18Ni9
B B
TIG
Z10CNT18 Z10 CN Nb18 or Z3CN18
1Cr18Ni9Ti H1Cr19Ni9Ti
00Cr19Ni11 HOOCr18Ni9
GH3030 HGH3030
Copper brazing：brazing filler
20 45 metal H62
OOCr19Ni11 40CrNiMo Flux YJ-3
Flame As required in
brazing drawing
1Cr18Ni9Ti 15CDV6 Silver brazing：
T4 A8CuZnCd16-16-18
Agent 102
1.7.2 Aluminum alloy

Welding
Matrix Metal Filler Metal Remarks
Procedure
L1—L6 L1—L6
LF3 LF3
LF5 LF5 or LF6
LF6 LF6
LF21 T1G LF21 or LT1
5086 Wire 5056 or AG5
LD2 LT1 or LD2
LY12 LT1
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2 Contact Welding of Steel, Titanium, Aluminum Alloy

Operating Instruction Manual of Spot Welding or Roll Welding，Resistance Welding as per
MR3383
SY-52 Operating Instruction Manual of Structure Steel and Stainless Steel Resistance
Spot Welding and Seam Welding
SY-54 Operating Instruction Manual of Aluminum Alloy Resistance Spot Welding and
Seam Welding
2.1 Aluminum and aluminum alloy
2.1.1 General
— Welded joints obtained by contact resistance welding can be divided into 4 types：
A, B1, B2 and C.
Type A：This type of joints has an auxiliary function，and the welded joints that are not
only unable to directly service the safety of aircraft，but also unable to
indirectly affect a very critical part due to their presence on this part .
Type B1：This type of joints can connect an auxiliary part to a critical Para. The less
stressed joint (for example：joint of some stiffeners on bearing skin ).
Type B2：Strength or durability of this type of joints can directly service the correct
performance and safety of structure, of which the design should make sure
the given number of defects of the dot welded joint will not be able to cause
weakening of structure ， and not to cause specified strength in
noncompliance with the actual strength.
Type C：The strength of this type is helpful to the safety performance of aircraft，it is
not allowed to have many, even a few poor quality weld dots (for example：
Wing spar cover on the wing spar web).
Contact resistance welding procedure of type C can only be used in a special case. This
procedure must be approved by “STAe′” (Aviation Department) after acceptance test
report delivered.
2.1.2 Form of contact resistance welding
— Spot welding with by general electrode
……Symbol：RP
— Spot welding by roller electrode
……Symbol：RPM
— Seal seam welding by rolling electrode
……Symbol：RM
2.1.3 Weldable alloys
— Can weld the same kind or following brands of alloy：
LY12CZ.2024.LD2CS. anti-rust aluminum
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L5，5052，5056 joints can be allowed in type A or particularly in type B1.
Note: As weld dot shape is not very obvious，so contact resistance welding of these
metals is very difficult. Such assembled part can only be carried out by an exceptional
method.
2.1.4 Relative arrangement of weld plate
2.1.4.1 Number of allowable layers
— Structural part: 3 layers
— Fuel tank：2 layers
2.1.4.2 Thickness of joint
— The contact resistance welding will be limited by dimensions and shape and
welding machine capacity of assembled parts.
a The thinnest joint can be welded：
0.3+0.3mm
b The thickest weldable：
3.2+3.2mm (as per capacity of welding machine).
Thickness combination is proportionally decided：
Total thickness of joint maximum 4mm
The thickness of thinnest external sheet
2.2 steel and titanium material
2.2.1 General
—Welded joints obtained by contact resistance welding can be divided into type A and
type B
In addition，welding joint divided into type B is be classified as type B1 and type B2
based on the extent of stress that they bear.
Type A：This type has an auxiliary function，a weld joint that does not directly service
the strength, safety or operation of aircraft such as paddle.
Type B：This type of joint has essential and specially essential function, and they
directly provide weld joint for the strength, safety or operation of aircraft
such as landing gear, engine mount, and turbo engine combustion chamber.
Type B1：This type of joint is not the weld joint to provide safety of parts such as bead of boss.
Type B2：This type of joint is the weld joint that directly provide correct operation
performance of parts such as seals, stiffeners.
2.2.2 Form of contact resistance welding
— Spot welding with by general electrode
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……Symbol：RP
— Spot welding by roller electrode
……Symbol：RPM
— Seal seam welding by rolling electrode
……Symbol：RM
2.2.3 Weldable metal
— Steel : 20；15CrMnMoVA；1Cr18Ni9Ti；OOCr19Ni11；1Cr17Ni13.
— Titanium: TA2.
— Steel spot welding or seam welding with carbon content of exceeding 0.16％ or has
quenching capability can only be temporarily authorized (for example ，
20.15CrMnMoVA).
— Titanium can be welded with corrosion resistant steel.
2.2.4 Relative arrangement of weld plate
— The total thickness of one joint should not be 4 times larger than thickness of
thinnest external sheet
— The quantity of joined sheets should be limited to 4 layers.
— The special cases of not following this rule should be approved by the test.
2.2.5 Arrangement of joints (Fig.2)
— Part drawing A—Recommended joint ；
— Part drawing B—Feasible joint, but should be avoided.
— The dimensions should follow dimensions specified in drawing
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Fig. 2Thinnest Weld seam

A A1 A2 B B1 C D H1 H2
sheet min.
spacing
Min. Min. Min. Min. Min. Min. Max. Max. Min.
(mm) (mm)
0.3 5 6 6 12 11 10 13 55 20 8
0.4 5 6 6 12 11 10 13 55 20 9
0.5 5 6 6 12 11 10 13 55 20 10
0.6 5 6 7 12 12 10 15 55 30 11
0.8 6.5 6.5 7 13 13.5 13 15 55 30 12
1 7.5 7.5 7.5 15 15 16 15 55 30 15
1.2 8 8 8 16 16 17 17 55 40 16
1.6 8.5 8.5 8.5 17 17 18 17 55 40 19
2 10 10 9 20 19 22 17 55 40 22
2.5 11 11 22 24 55 25
3 15 15 30 32 55 30
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ASSEMBLING OF BUSHING ON SUPPORTING PART
1 Assembling Bushing on Supporting Part

1.1 Selection of assembling method
The assembling method depends on necessity of assembling. The selection of assembling
method will be determined by operators according to introduced equipment. In all the
cases, it is necessary to carefully check bushing and bore diameter (sizes, surface
conditions and roundness, etc.). And then, wipe it using cloth dipped with solvent
(trichloroethylene, etc). Under the condition of different metals, apply M3-1 or other
compounds specified in the relevant chapters and sections, to the fitting surfaces of
assembled parts.
Four assembling methods can be used：
— Press assembling
— Expansion assembling
— Contraction assembling
— Expansion and contraction combination assembling
1.2 Press assembling
This method will not change the physical and chemical property of parts in assembling,
and generally, will not change their metallographic structures. Sometimes the required
fitting performance is lowered due to variation of contact surface. Its reason is the wears
or scratches of soft parts surface caused by hard parts surface.
1) Method (see detail A in Fig.1)
Prior to assembling, make sure the assembled parts (bushing，sleeve, etc.) are
correctly aligned to 正 bore diameter center. It would be best to use a king of
assembling tool that is able to align the part with bore diameter center and easily be
pressed in.
1 Push-up washer
2 Bushing to be fit in
3 Pilot mandrel
4 Spring
5 Bracket
6 Parts
2) Assembling method without using a press machine (see detail B Fig.1)
a) Assembling the first bushing
b) Assembling the second bushing
1 Nut
2 Thrust washer
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3 Spacer block
4 Guide sleeve
5 Bushing
6 Washer
7 bolt
1.3 Expansion assembling
This assembling is t o fit a contained member into external member expanded by
preheating. During cooling period, an ideal fitting can be obtained due to shrinkage of
external member.
Note: If the required temperature may vary metallographic structure of metal and change
surface state or make parts deformed，then this method can not be used .
1.3.1 Expansion assembling (see detail C in Fig.1)
— The expansion of t he part or other structural members of taking in bushing
expansion is obtained by heating：
• In furnace
• In oil tank
— Heating temperature depends on interference of fit (△L).
— In order to fit bushing，parts must be heated，so as to increase “L”，to make it
become L2=L+△L(△L which is maximum interference of fitting ).
1) The required expansion value shall be determined as per materials
— Light alloy ：
• Small limits of expansion: Heating temperature should not exceed 80℃.
• Big limits of expansion：Heating temperature shall be determined by different
alloys.
• Heating time should be accurately controlled to the time needed to obtain an ideal
temperature.
— Steel ：
• Heating temperature should always be lower than tempering temperature.
• Heating time and temperature should be accurately controlled to the required
values.
2) Use furnace heating expansion
— Heat the external parts in furnace (if required，be heated with assembling
fixture). The heating should be carried out uniformly and slowly to prevent
deformation.
— When assembling different material and using insulation compound，its heating
temperature should be lower than failure temperature of compound, that is, when
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M3-1 factice is used, the temperature is 250℃.

3) Method
— Under condition of assembling different materials，it is required to coat parts with
M3-1 factice or any other compounds specified in relevant chapters and sections.
—A press machine should be used for assembling.
— The method specified in Para. 1.2 can be used.
1.4 Contraction assembling
This method of operation is to cool the contained member，making it be momentarily
shrunken，then fit it into the external part. As the temperature rising, the contained
member will be expanded to constrict the surface and lock, thus obtaining a desired fitting.
This method is not applicable to all steels.
1.4.1 Contraction assembling
— The cooling sources used for contraction assembling are as follows：
• Liquid nitrogen (it is most commonly used)，boiling temperature：-195℃
• Solid carbon dioxide，temperature: -80℃
— Nitrogen consumption used for cooling depends on weight of part (to cool steel of
1kg requires 1L of nitrogen). When the part reaching temperature of liquid
nitrogen ， no measuring instrument is required for determination. With parts
immersed，operators shall pay attention to boiling bubbles，and when bubbles are
terminated，the part will reach the temperature of liquid nitrogen.
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Fig. 1
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Note:
The cooling may make heat treated parts become very brittle, so the collision of parts
must be avoided before they recover to the normal temperature.
Caution：
— Never block the liquid nitrogen storage tank or impregnation tank.
—Never put such storage tank or impregnation tank in a sealed container.
— Procedure：
• Under condition of using different materials, it is required to coat the interior wall of
external member holes with M3-1 factice or any other compounds specified in
relevant chapters and sections
• Fit the bushing on an assembling tool (see detail D in Fig.1).
Note: For a contained member light in weight，its integrated assembling tool is best to
be made of metal which has higher thermal conductivity and specific heat.
— Immerse tool contained with a bushing into the cooling agent.
— With parts immersed into the liquid nitrogen, wait until the air bubbles are ceased.
At this moment, part has been adequately cooled.
— After taking parts from the liquid nitrogen, it is required to conduct the assembling
as quickly as possible，and correctly fix the position of bushing. Under some tight
fitting conditions，the bushing be gradually driven in by pressure or using a wood
hammer.
1.5 Expansion and contraction combination assembling
The combination assembling will be used at the same time as the method described in
Paras. 1.3 and 1.4, which is particularly suitable and necessary for the tight fit.
This is required to cooling the contained member at the time while heating the external
member .
Special case, that is, when fitting the contained member into external member, the
temperature of external member has dropped，and at the same time, the temperature of
contained member goes up again，and at this moment, it is allowed to use the pressure
assembling.
1.5.1 Expansion and contraction assembling
This method includes：
— Heat external parts as described in Para. 1.3.
—Immerse external parts into cooling agent as described in Para. 1.4
—Assemble the cooled bushing as described in Para. 1.2.
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Table1 . Installation of Steel or Bronze Bushing on Light Alloy Supporting Part

Material of supporting part 2024 7075 2014 5052 5056 Remarks
Temperature
used Coated with
M3-1 190 0+5 135 0−5 185 0+10 250 0+10
expansion
supporting
part Without
M3-1
Assembling
Material of supporting part 2024 7075 2014 5052 5056 Remarks

Temperature Supporting part ≤90 ≤80 ≤80 ≤80 ≤0
Contraction To be coated with
/expansion M3-1
Combination Bushing -195(liquid nitrogen )
assembling -80(solid carbon dioxide)
α Steel 9×10-6 P P +15℃
Expansion Bushing Bronze -6 α
coefficient 16×10 P P
-195℃
μm/ +200℃
mm/℃ Supporting part 23×106 P P α
+15℃
Note:1 Compound：Unless otherwise specified in relevant chapters and sections，M3-1

will be used.
2 Time of parts held in furnace depends on their volumes，which should be
accurately controlled to required time ， so as to reach their required
temperature .
Table2 . Installation of Steel or Bronze Bushing on Steel Supporting Part

30CrNi4MoA 40Cr 35CrNi4MoA 35 CD 4
R× R× RX R× Z. 12C13 15Cr R×
R×103
103 103 103 103 Z.30C13 103
P P
bar
P P P P P P P P P P
Material of supporting part bar bar NiMO bar bar MnMo bar
Z.3CN-
18 169~
180~1 157~ A 113~ < VA 108~
196
22 186 127 176 127
Temperature Bushing R> < < < < < < < < <
1)Contraction 160×10bar 180 180 180 180 180 180 180 180 180
/expansion Supportin R < < < < < < < < <
combination g part 160×10bar 250 180 250 250 180 250 250 250 180
assembling < < < < < < < < <
2)Expansion Bronze 250 180 250 250 180 250 250 250 180
Supporting -195℃ (liquid nitrogen )
part Bushing -80℃ (solid carbon dioxide)
α expansion steel 9×10-6 P P
+15℃
coefficient Bushing Bronze 16×10-6 P P
-195℃
μm/ +200℃
mm/℃ Supporting part 12×10-6
+15℃
P P
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Note:
1 Time of parts held in furnace depends on their volumes，which should be
accurately controlled to required time，so as to reach their required temperature
2 Compound：Unless otherwise specified in relevant chapters and sections，M3-1
will be used, which should be used in various conditions of assembling
different materials (bronze, steel ) or under condition that one of parts has no
protective layer (hole or bushing).
1.5.2 Preventive measures to be taken when using liquid nitrogen
There is possibility of liquid drops splashed out, but there is risk to form a gaseous
layer between the skin and coolant liquid which can protect skin and can prevent burns
caused by contact.
Caution: Never touch the metallic body which is cooled by impregnating，as the
skin of operators may be injured for there is no gaseous protective layer.
During handling process, it is required to use the pliers or put on the
protective gloves.
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ASSEMBLING
1 Assembling Using Plain Bolt and Nut

— The indicated torque is applicable to normal tightening nut.
— In very special case，may tighten bolts；provided that the following conditions are not
involved，the maximum torque is still applicable：
• Tight fit bolt.
• Non-hexagonal head screw ：These screws shall be tightened and checked using a
standard screwdriver，and no torque measurement is to be made .
— Buckling of several layers of metal sheet should be taken into consideration. First of all,
pre-tightening should be carried out, then the second tightening shall be performed
according to the marked torque.
1.1 Tightening sequence (see detail A in Fig.1)
Unless otherwise specified in every Assembling Manual，upon bolts installed and roughly
tightened，nut should be tightened according to the in numerical order.
1.2 Check procedure of torques
The check is done only by spot checking，and it is always conducted in direction of
tightening, of which procedure is as follows：
— Distinguish the position of nut relative to assembly，and identify the nut and assembly
with marks.
— Loosen：Use plain wrench to loosen the nut by 1/2 turn.
— Again use torque tension wrench to tighten the nut and read out the torque.
— Tighten the nut or bolt head for second time，mark non-coincidence value which
should not exceed 2mm
Caution: Never check torque by loosening a nut.
1.3 Check torque wrench and adapter
The torque wrench and adapter should be checked at least once per month on the proper
tester.
tolerance：Calibration should be accurate to +5%.
1.3.1 Use adaptor
When the nut can be tightened only by an adapter，it is necessary to take some measures
to eliminate error of torque load in application and reading.
Adapter should be correctly laid, so as to locate the center line of tightened hexagonal
or fork joint along the axis of torque wrench.
— The length of adapter shall always be less than the length of torque tension wrench.
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— The special case may use the adapter with an eccentric shaft，but deviation angle
should not exceed 15°, (see detail C in Fig.1).
—Never put the adapter in perpendicular to torque wrench.
— When using an adapter, if the tightening moment applied to nut is not the same as
the reading of torque wrench, then it is necessary to prepare a corresponding chart
for applied torque vs. wrench and adapter combined torque reading.
1.4 Specification for reusing of nuts and bolts
1.4.1 Reused screws, nuts and screw pins
When every male thread part being removed，which should be carefully checked . All
parts and threads and screw bolts that have any defects described bellow should be
discarded and replaced：
— Pre-shrinking，bending, torsion.
— Peeling, scoring.
—Tolerance limits of wear are exceeded.
— Protective layer has been damaged.
— Indentation.
Note:
Reusing of the bolts and pins used in close tolerance fitting (e.g. H7-P6) should not be
more than twice.
1.4.2 Specification for reusing of double lock nut (crown nut of internal nylon lock).
Prior to reusing the nuts：
— Make sure the nylon lock is not over-damaged.
— Fit the nut with hands：
• If a nut can be easily tightened，then it should be discarded.
• If a nut is hard to be tightened and fails to be tightened，then it can be reused. (in the
workshop，the minimum lock torque value can be read by using a torque wrench).
1.4.3 Requirement for installation of new or used self-lock nut

1.4.3.1 Special preventive measures to be taken prior to installation of nuts
It is prohibited to：
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— Use phenolic cleaning agent to clean nuts (Nylotop nut).

— No matter what type it is, tapping shall be made in self-locking nut during the
installation or before reinstallation.
1.4.3.2 Check procedure for installation and reinstallation of nuts with diameter of
exceeding 9.5mm
No matter what type of self-locking nut is used (metal ,fiber glass or nylon)，it shall
be checked with hand tightening. If the self-locking part can be screwed in the
threads of screw，then the nut must be discarded.
1.4.3.3 Check procedure for installation or reinstallation nuts with diameter from 10 to
20mm
No matter what type of self-locking nut is used, after the self-locking part of nut
can be completely screwed in the threads of screw，the minimum torque can be
measured by loosening nuts；and however，its bearing surface should not be in
contact with the structural components to be fixed.
Diameter of nut Minimum tightening torque
(mm) (m . decanewton)
10 0.12
12 0.18
14 0.25
16 0.37
18 0.53
20 0.77
1.5 Standard torque load

1.5.1 General
The standard torque load is only provided in this section. The special torque load used
for maintenance will be described wherever it is needed.
1.5.2 Applicable torque load
Note: This torque is not applicable to non-hexagonal head screw.
— When there is no description in the drawing provided, the following torques should
be used for standard steel and titanium bolt and nut “Dry” installation. They will
use the yield strength(YS) of bolt material as base，and applicable to various kinds
of and grades standard nuts. These values are given in “m-Decanewton” (mdaN)
Table 1— Torque values are used under “Dry” state
“m-Decanewton” (mdaN)
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Thread With hexagonal nut With self-locking nut

Steel bolt Steel bolt Titanium
alloy bolt
Diameter Pitch T-A4M
and
35NC6 30NCD16 35NC6 30NCD16 T-A6V
ISO SLn Min Max Min Max Min Max Min Max Min Max
4 0.7 0.75 0.2 0.25 0.25 0.3 0.25 0.3 0.3 0.35
5 0.8 0.9 0.3 0.4 0.4 0.5 0.4 0.5 0.5 0.6 0.35 0.45
6 1 1 0.6 0.75 0.75 0.9 0.75 0.9 0.9 1.1 0.70 0.85
7 1 1 1.25 1.25 1.50 1.25 1.50 1.50 1.75
8 1.25 1.25 1.5 1.9 1.9 2.3 1.9 2.3 2.3 2.7 1.50 2.00
10 3.4 4.1 4.1 4.8 4.1 4.8 4.8 5.5 3.50 4.50
12 6.3 7.5 7.3 8.5 7.3 8.5 8.3 9.5 8.3 9.5
1.5 1.5
14 10 12 11.5 13.5 11.5 13.5 13 15
16 16 19 18 21 18 21 20 23
Note:
The “Dry” state means there is no special lubricant (or sealant) on threads or bearing
surfaces. When the lubricant is used, a correction coefficient shall be added to “Dry”
value.
Table 2: Torque values used under the “Dry” state, which is calculated as per
“m-Decanewton” and used for ISO bolts and nuts (inch)
Note:
Requirements for operation are the same as that of BNAE standard metric bolts. (For
material of BNAE bolts, see NSA501.16)
With hexagonal nut With self-locking nut
Steel bolt Steel bolt
Number of 35 NC 6 30 NCD 16 35 NC 6 30 NCD 16
Thread diameter threads/inch TS：88hbar TS：108hbar TS：88hbar TS：108hbar
YS0.002 YS0.002 YS0.002 YS0.002
73hbar 88hbar 73hbar 88hbar
Min Max Min Max Min Max Min Max
·190(N*10) 32 0.30 0.40 0.40 0.50 0.40 0.50 0.50 0.60
·2500(1/4) 28 0.70 0.90 0.90 1.10 0.90 1.10 1.10 1.30
·3125(5/16) 24 1.60 2.00 2.00 2.50 1.80 2.20 2.20 2.70
·3750(3/8) 24 2.70 3.50 3.30 4.00 3.00 3.80 4.00 5.00
·4375(7/16) 20 4.50 5.50 5.50 7.00 5.20 630 6.70 8.00
·5000(1/2) 20 730 8.50 8.50 10.00 8.00 9.50 9.50 11.50
·5625(9/16) 18 10.50 12.50 11.50 13.50 11.50 13.50 14.00 16.00
·6250(5/8) 18 14.00 16.00 17.00 20.00 16.00 19.00 19.00 22.00
·7500(3/4) 16 24.00 28.00 28.00 32.00 27.00 31.00 32.00 37.00
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1.5.3 Selection of bolt grade

— 35NC6：minimum tensile strength (TS) is 88 Hectobar；
minimum yield strength(YS) is 74Hectobar；
— 30NCD16：minimum tensile strength (TS) is108Hectobar；
— T-A4M：minimum tensile strength(TS) is 93Hectobar；
— T-A6V：minimum tensile strength(TS) is 88Hectobar；
Minimum yield strength (YS) is 8Hectobar.
The torque value is still applicable to all grades of steel that have the same mechanical
characteristics. Under different characteristics，but in the same state，the torque values
are proportional to yield strength.
1.5.4 Torque load value of slotted nuts
Thick nut P/N22451BC……L
Thin nut P/N22543BC……L
— Following torque values are applicable to 35NC6 steel screws and nuts of “Dry”
installation. This value is given in “m-Decanewton” (mdaN).
Thin nut Thick nut
Thread diameter Refer to 22453BC……L refer to 22451BC……L
and
thread pitch Minimum Maximum Minimum Maximum
torque torque torque torque
5×0.8 0.15 0.30 0.20 0.40
6×1.00 0.35 0.55 0.45 0.75
7×1.00 0.45 0.95 0.50 1.20
8×125 0.55 1.35 0.80 1.80
10×1.50 1.10 2.80 1.90 4.00
12×1.50 1.90 4.60 3.60 7.30
14×1.50 3.80 7.60 5.90 11.80
Note: For 22451 and 22453 nuts, see ASN523, 35, ASN523.36
1.5.5 Torque load value of double locking slotted nut

Thick nut P/N52347BC……L
Thin nut P/NZ5346BC……L
— Following torque values are applicable to 35NC6 steel screws and nuts of “Dry”
installation. This value is given in “m-Decanewton” (mdaN)
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Thin Nut Thick Nut

Thread diameter
Refer to 52346BC……L Refer to 52347BC……L
and
thread pitch Minimum Maximum Minimum Maximum
torque torque torque torque
5×0.8 0.20 0.35 0.30 0.50
6×1 0.45 0.65 0.60 0.90
7×1 0.60 1.10 0.80 1.50
8×1.25 0.80 1.60 1.30 2.30
10×1.5 1.60 3.30 2.70 4.80
12×1.5 2.80 5.50 4.80 8.50
14×1.5 5.20 9.00 7.60 13.50
1.5.6 Torque load value of fastener in metal or NOMEX sandwich structure board
Unless otherwise specified in task card, all assembling in flat sandwich structural board
hole，torque load value should be 50％ of standard value given on Section 1.5.2.
1.6 Lubricant and sealant should use requirement for thread assembled unit (see Table II)
— Bolts，nuts and washers：Cadmium plating (titanium excepted).
— Thread：Mechanically machined or rolled.
— Thread and bearing surface：Cleaning.
— Torque load：Applied to the nuts.
— When using a lubricant，new torque load value is obtained by multiplying the “Dry”
torque load value with the correction coefficient of lubricant used.
For example：lubricant ( correction coefficient is 0.55), the minimum standard dry torque
loading value is 4.10, then the torque loading value to be used is 4.10×0.55=2.25
m-Decanewton.
Important note：These correction coefficients are not applicable to self-locking nuts.
Note: When installing fasteners, it is prohibited to use animal oil.
When applying the sealing compound，check the torque value under the following
conditions：
— PR1005 should be applied within 20 minutes after installation
— PR1221 and 1321should be applied within 4 hours after installation.
Table Ⅱ- Correction coefficient of lubrication and chemical reaction products
Lubricants：
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Aeronautical
Purposes or Types of Standard of
standard Brand Coefficient
Product Manufacturer
AIR
1503 Protective oil of piston ESSO Aero BANOX 624 type 0.50
engine Rust Ban 625 0.75
Rust Ban 632 0.55
3565 Pure mineral oil used for
Commercial Vaseline 0.65
metal bonding
4205 High melting point SHELL No.5 lubricant 0.50
lubricant ESSO Audck 260 0.50
4206 Graphite added lubricant SHELL No.8 lubricant 0.40
Barbatia n°4 0.50
ESSO DTD 806 Aero lubricant 0.50
SPCA CZG compound 0.85
4207 Lubricant of wide SHELL No.16 lubricant
temperature range 0.55
(-40℃+175℃)
4210 “Limit Pressure” low SHELL No.7A lubricant
0.50
setting point lubricant
4214 Hydrochloride resistant SHELL No.10A lubricant 0.50
lubricant ESSO Carum 35 0.50
BP No.32 Aero lubricant 0.65
4215 General purpose lubricant MOBIL No.23 lubricant 0.45
BP No.33 Aero lubricant 0.50
ESSO No.1 Aero general
0.50
purpose lubricant
SHELL No.68 lubricant 0.55
4217 Diester molybdenum IMPEX Graisse Ailex 0.45
disulphide lubricant SHELL No.17lubricant 0.50
4225 Diester general purpose MOBIL No.22 lubricant 0.45
lubricant BP No.31 Aero lubricant 0.50
4226 Very low temperature SHELL No.1 lubricant
0.55
lubricant
4247 Thread anti-seize ESSO No.1 Aeronautical
0.40
compound anti-seize compound
8136 Hot applied soft ESSO RuSt ban 324
0.45
protective agent
MIL G Lubricant of wide MOBIL No.24 lubricant
25013 temperature range 0.80
(-54℃+232℃)
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Fillers：
Standard of
Characteristics of Filler Brand Coefficient
Manufacturer
Anti-corrosive matters used fort
installation of bolts and nuts on CELLOLAC 6856F glue 0.75
magnesium support
Infiltration of air and kerosene is not PR 1221
French 1.60
allowed PR 1321
Connector
Infiltration of kerosene is not allowed PR 1005 1
1.7 Torque marks of nuts and bolts (see detail B in Fig.1)

— For the special and standard torque loads, use a red line as the mark which is
provisionally selected at will.
— The marks shall be retained only when the Aerospace Design Authority or Production
Authority specifies.
1.7.1 Mark of self-locking nut internally in straight or ellipse shape
1) On assembly
— Apply a specified torque load.
2) After assembling and fixing to a specified torque：
a) Hexagonal nut：
— At the end of screw，use a red paint line to mark the position of nut (with width
of about 2mm) on nut, washer and a fixed component.
b) Anchor self-locking nut：
— At the bolt head，use a red paint line to mark the position of bolt nut (with width
of about 2mm) on washer (it is rare even if any) and fixed parts.
Warning:
Upon fixed, the bolt should be at least extended one thread out of the nut. The
chamfer at bolt end is exclusive.
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Fig. 1
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CHECK OF SELF-LOCKING NUTS AND SCREWS
1 Check Procedure
1.1 General
This task card specifies the standard for using and reusing self-locking screws and nuts.
1.2 Geometric shape check
On assembly，threaded fastener should free from obvious dimensional deformation or a
wear of impairing the affectivity of.
Thread must be able to be tightened to the locking device.
All parts that are not up to the requirement should be discarded.
1.3 Functional check
When tightening a nut or screw，the torque load to be applied shall be equal to the
appropriate torque of locking parts between the point of whole thread extended out of nut
and the point of axial load applied to fastener (i.e. the clamping action starts) .
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Fig. 1
The curves in the Figure stand for：

(1)— Lock torque
(2)— Standard thread diameter
(3)— Minimum lock torque
(4)— Maximum lock torque
Note: If it is specified to use graphite grease or equivalent to lubricate the thread fastener，
then the maximum lock torque shall be reduced by 25％.
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GENERAL DESCRIPTION ON SAFETY AND LOCK OF ASSEMBLY
This section is to tell users about various procedures which are used for safety of shaft pin
as well as lock and safety of threaded assembly.
Shaft pin is locked with the following elements：
— Cotter pin
— Safety pin
Threaded assembly is locked and secured by using following elements：
— Self-locking nut
— Locking wire
— Locking plate
— Cotter pin
— Jam nut
— Buckle
— Peening lock
— “LOCTITE” compound (ASN502-02)
— “REZOLIN” compound
— Single constituent threaded lock anaerobic adhesive (Z9-0737-91)
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SAFETY OF SHAFT PIN
1 Safety of Shaft Pin

1.1 Safety using split pin（see detail A in Fig.1)
A washer (1) must be set between the assembly and split pin (2) when securing the shaft
pin by using a split pin.
The split pin should be fit as shown in detail A.
Select the split pin as per the diameter of shaft pin
Diameter of Shaft Pin Diameter of Split Pin Length Split Pin

(mm) (mm) (mm)
4 and 5 1.5 12
6 and 7 2 15
8 2 20
10 and 12 3 25
14 and 16 4 35
1.2 Safety using safety pin (see detail B in Fig.1)

Safety pin (1) can be used to safety the primary gearbox suspension support rod bolt (2)
or cowling fastener (3)
Note: Locating shaft pin is prohibited to use a safety pin.
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Fig. 1
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SAFETY WITH LOCKING WIRE
1 Safety with Locking Wire

1.1 General
— When the nuts, screw heads, plugs, pipe fittings, etc. are all provided with safety pin
holes, then these parts shall all be secured with locking wire.
—The locking wire used is made of softened, non-magnetic stainless steel Z3 CN 18.
1) Safety method (see detail A in Fig.1)
— Locking wire shall always be completely tensioned between the locked part and
connecting point (1).
— Pulling force applied should counteract the slackness (2).
— The end of locking wire should be twisted at least by 4 turns，with spiral line of
about 10mm；The spiral line should be folded along one of locked parts.
— After installation，locking wire should not be defects like tool marks or cracks.
— Each assembly should use a new locking wire.
2) Safety using double locking wire（see detail B in Fig.1)
—Safety form in most common use.
3) Safety using single locking wire（see detail C in Fig.1)
— When screws are too close to each other or arranged into a close geometric figure，
their safety can be performed using a single locking wire.
— Screw unrelated should be connected to flange or strut using a single locking wire
for safety.
if locking wire is short，near the part and not easily be damaged, then it is allowed to
use a single locking wire on pipe fittings for locking.
— For various kinds of pipe fittings that can be secured with a single locking wire, see
detail D in Fig.1)：
1— Straight pipe fitting
2— Plug
3— Drum pipe fitting
4— Directly installed pipe fitting
5, 6— Multi-circuit pipe fitting
7— Cross pipe fittings
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Fig. 1
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SAFETY WITH LOCKING PLATE
1 Safety with Locking Plate

1.1 General
The locking plate is a metal part which is installed under flat hexagonal nut or hexagonal
screw in stead of a washer.
The tab is to fix a locking plate to the part，by which to stop rotating of nut, screw or bolt.
The ring tabbed washer is used to lock the nut installed on the recessed thread shaft.
1.2 Application
1.2.1 Locking plate (see detail A in Fig.1)
— locking plate (1) applicable to：
• On edge of straight line (2)
• On edge of curve (3)
• On rib (4)
• On the lock hole (5)，tab (6) is to be cut off.
1.2.2 Tab washer (see detail B in Fig.1)
— When the lock hole (8) can be used，then safety using a tab washer(7).
1.2.3 ring tab washer（see detail C in Fig.1)
— When the nut is installed on shaft with recess thread(10，then safety using a ring tab
washer(9).
1.3 Description for folding the tab on flat surface of nut (see detail A in Fig.2)
— Insert a thin metal plate (1) to protective the part.
Prior to operation, bend the tab slightly or as shown in detail.
— Use tool (3) to crow it up.
— Fold the tab on nut (4).
Caution:
For titanium screw，use the pliers to fold the tab (to prevent dents).
— After tightening，nuts or bolt may have the position forms as follows (see detail B
in Fig.2)：
a) Two lock tabs on two planes.
b) Two lock tabs on one plane.
c) One lock tab on one plane，the other tab in use.
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Fig. 1
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Fig. 2
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SAFETY WITH SPLIT PIN
1 Safety with Split Pin

1.1 General
When securing with a split pin，following instructions should be followed .
— Split pin diameter must be in consistence with bolt hole.
— If necessary, use pliers to cut before bending the legs of split pin.
— It is prohibited to lock the split pin on an open drive unit or nearby.
— It is prohibited to hit the pin head inserted in recess and also prohibited to bend pin
legs by heating (risk of cracks).
— After locking the split pin，the pin must be reliable.
Caution:
— For all the bolts and screws with castle nuts，split pin must be locked as soon as nut is
tightened.
— The subsequent removal should not serve as the reason for putting off to install the
split pin immediately.
— Split pin should not be reused.
1.2 Selecting split pins according to bolt diameter
Diameter of shaft pin Diameter of split pin Length of split pin
(mm) (mm) (mm)
4 and 5 1 12
6 15 15
7 and 8 1.5 20
10 and 12 2 25
14 3 30
16 3 35
18 and 20 4 40
22 4 50
24 5 50
27 and 23 5 60
39 6 70
45 6 75
1.3 Safety methods (see Fig.1)

Figure 1— it is recommended to use
Figure 2—it is allowed to use
Figure 3—it is prohibited to use
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Fig. 1
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LOCKING WITH JAM NUT OR TOOTH WASHER
1 Locking with Jam Nut (see detail A in Fig.1)

This safety mode is specially used for safety design and parts at bar end.
Tightening torque of jam nut (2) is the same as that of nut (1).
2 Locking with internal tooth washer or external tooth washer (see detail B in Fig.1)
The internal tooth washer or external tooth washer is specially used for safety of connection
of electric wires.
Illustration 1—External tooth washer
Illustration 2—Internal tooth washer
Fig. 1
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PEENING LOCK
1 Peening Lock Nut

1.1 General
Mid strength un-removable hardware should be locked by using this method when
self-nut can not be used for some reasons.
Prior to peening, the bolt end should be equated and the equated place should be applied
with one protective coat.
1.2 Peening method
Two peening methods are used：
1) No special tool is used for peening (see detail A in Fig.1)
— After chipped, the bolt end must be protruded by 0.4—0.6mm.
— Peen a bolt at three positions, so that the metal of the bolt can be pressed on nut.
— Protect the chipped end.
— Carry out the screwing off test at will.
2) A special tool is used for peening (see detail B in Fig.1)
— After chipped, the bolt end must be protruded out of nut by 0.1diameter.
— Use the special tool to control the peening.
— Protect the chipped end.
— Carry out the screwing off test at will.
Note:
It is prohibited for the steel part which the tensile strength TS is higher than
120kg/m, to use this kind of peening method.
Caution: The following types of peenings are prohibited：
— Hammer the bolt end.
— Peen the nut to make the metal pressed from nut on bolt.
— Peen thread profile that is common to the bolt and nut.
Peen a bolt at more than three positions.
Fig. 1
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LOCKING OF SLOTTED NUT
1 Locking of Slotted Nut

Use two kinds of following locking methods：
1.1 Tabbed washer (see detail A in Fig.1)
Tabbed washer should be installed under slotted nut on threaded and slotted shaft.
Note:
Tab should be used only once, which should be discarded upon removal.
1.2 Snap ring (see detail B in Fig.1)
Snap ring is used to lock split nut.
It should not be used on the rotary assembly the rotating speed of more than 3,000 r/mm.
Fig. 1
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SAFETY OF TURN-BUCKLE
1 Safety of Turn-Buckle
1.1 General (see detail A in Fig. 1)
Turn-buckle and threaded end are provided with a recess locked with steel wire lock pin，
so as to secure and lock the assembly .
1.2 Security steps（see detail B in Fig.1)
— Align the recess on threaded (2-5) with one of two recesses on turn-buckle (4).
— Inset the straight line section of lock pin (1) into thread recess and turn-buckle recess.
— Fit the lock pin hook (3) into the safety hole of turn-buckle，apply a pressure to the
hook so as to lock it.
— Lightly pull the hook to check the connection of lock pin.
Note: Two lock pins can be installed on the same side (b) or both side (a) of the
turn-buckle.
Precautions：
Systematically replace and remove lock pins.
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Fig. 1
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SECURITY WITH LOCTITE
1 Security with Loctite

1.1 General
LOCTITE compound has several grades which are distinguished as per their viscosity and
lock-up force. Each type of them is in a special color，so that they can be easily
recognized. This product is provided in liquid state，it has a hardening characteristics
when in contact with metal isolated from air. In order to obtain a complete hardening, the
hardening can be sped up by heating (to be hardened at 100℃ for 15min). After
completely hardened，like paint and varnish solvent, “LOCTITE” compound is water
proof, fuel and lubricating oil resistant.
1.2 Main LOCTITE grades used for assembling
Caution:
Select the grade of LOCTITE sealing compound as required.
Application LOCTITE Accelerator Provided
To fix bushing bearing 307 747
With spherical coupling 324 707
Normal locking wire 242 T or N
Weak locking wire 222 T or N
Strong locking wire 270 T or N
424 T or N
(1) The product is generally sold by Le Tai Corporation in China

(2) The previous LOCTITE standard product code is the same as products in column (1)，
only the code of standard has been changed.
(3) Very much like the products in column (1)，their replacement can made without taking
special preventive measures.
(4) The products of substituting for LOCTITE products no longer manufactured can be
used only after assessment by central laboratory (DCQ/L) or approval by the relevant
design department.
1.3 Active agent and accelerator
In the environment temperature, solidification of “LOCTITE” compound can be activated
by pre-impregnating or pre-spray “LOCTITE”N or T to treat threads.
— “LOCTITE”N (active agent)
“LOCTITE”N is a kind of green concentrated active agent，and this kind of active agent
shall be used in trichloroethylene solvent as per ratio of 5％volume.
The minimum drying time shall be 5 minutes before applying LOCTITE compound to
completely dried metal.
— When the environment temperature is 15℃，the minimum solidification period of
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LOCTITE compound is 2h：

Caution:
“LOCTITE”N compound should be designated to be used for cadmium
plating and galvanized metal and stainless steel.
— “LOCTITE”T (accelerator)
“LOCTITE”T is a violet concentrating agent, which is used for solution
comprised of following solvents as per 5％volume：
• 60％ trichloroethylene
• Butyl group alcohol as per 40％v volume
• The minimum drying time is at least 10 min before applying LOCTITE
compound to the completely dried metal.
When the environment temperature is 15℃，the minimum solidification period of
LOCTITE compound is 4h
Note: “LOCTITE” T compound can be used for other metals of no protection layer with
stainless steel excepted.
1.4 Safety steps and application scope（see detail A in Fig.1)
Caution:
According to the type of assembling，use a kind of “LOCTITE” gasket
scavenging agent to make the part normally be separated without applying
a abnormal force or damage to the part，and it can also be heated to 250℃
and above for disassembling.
— Use one kind of non-grease solvent to degrease.
—Use the “LOCTITE”N or T compound as described in Para. 1.3.
—Use LOCTITE compound according to one of two methods below：
a) Using impregnating method：
— When a large quantity of LOCTITE compound，the impregnating method can be
used.
— The steel screws and nuts impregnated according to the above method can be stayed
at most 8 hours in contact with air that is because the compound can be solidified
only when the nut is installed to screw.
Note: For the copper alloy，the stay time shall be at most 4h.
b) Individual application (see Item 1 in detail A)
—Prior to installation，pour a drop of LOCTITE compound on the nut thread.
Caution:
For the screw of power supply contact (see Item 2 in detail A)：
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— Upon a nut tightened on screw，then：

• Pour a drop of LOCTITE compound on the part extended out of the tightened
nut.
• This drop of compound will be penetrated through capillary absorption.
— Prior to curing, use a wiper to clean the surplus compound on connector
Caution: When LOCTITE compound is in contact with paint, polystyrene, cellulose
or vinyl plastics and varnish，any compound drops should be wiped clean
immediately.
c) Examples for proximity application LOCTITE compound (see detail B in Fig.1)
— Item a：Assembly with screw and nut (with washer removed).
— Item b：Locating screw (with lock nut removed).
— Item c：“LOCTITE” compound locked stud bolt.
— Item d：Standard screw (with washer removed))
— Item e：Use “LOCTITE” compound to lock the ball bearing.
— Item f：Fuel bottom bolt (remove blind hole, use compound to ensure air tightness).
1.5 Check the installed force-applied parts
— Determine if “LOCTITE” compound has entered into the force-applied portion of an
assembled part (ball bearing, spherical connector……etc). This kind of inspection will
be easier by using violet ray radiation (compound sends out fluorescent light).
1.6 Soak-cleaning “LOCTITE” compound
After removal, the treated part can be soak cleaned by immersing it into a hot caustic soda
solvent，or cleaned using the product ARDROX2526.
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Fig. 1
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LOCKING OF TYPE 4 L/HOTELIER END CONNECTOR
1 Locking of type 4 L/HOTELIER end connector

1.1 General
For the sake of safety, lock the type 4 L/HOTELIER end connector, to prevent the end
connector screwed off the ball joint, and enable the end connector to eliminate any
assembly clearance wear between ball joint and end connector, thus maintaining the basic
function of the system.
1.2 Technological process (see Fig.1)
— Adjust the rod (5) fitted with end connector(2).
— Tighten nut(4).
— Pass lockwire (6) through hole (3) .
— Twist lockwire about 5mm and above.
— Raise both ends of lockwire up and inert them into lead sealing (7).
— Use a special pliers to compress the lead sealing.
— Cut off surplus lockwire.
(8) as shown in Fig. is a secured end connector.
Fig. 1
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LOCKING OF DRIVE SYSTEM WITH “SHUR LOCK” NUT
1 “SHUR LOCK” Nut (See Fig.1A)

T T T T
1.1 Pre-installation Measures

Fit the nut onto shaft (1) from up to down, check that there should be no gap between saw
teeth on shaft (1) and lock device (2).
Caution: In continuous SHUR LOCK nut numbering, their diameters are in slight
difference.
1.2 Installation
— Refer to descriptions on chapters and sections in relevant manuals.
— Lock in accordance with detail A：
Fig.1A
1 Shaft
2 Lock washer
3 Nut
4 Lock tab
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LOCKING OF DRIVE SYSTEM WITH “STA LOCK” NUT
1 “STA LOCK” Nut with Lock Ring

1.1 Preparation prior to installation
Prior to installation of lock ring (1)，check there should be no clearance between saw tooth
on shaft (4) and locking device.
Note: In continuous STA-LOCK numbering，their diameters are slightly different .
1.2 Installation (see Fig.1)
Caution:
Check lock washer shall be installed in the proper direction.
— Installation shall be performed in reference to description in the
relevant chapters and sections of the manual.
— Use the installation tool specified in the relevant chapters and sections.
1.3 STA-LOCK nut assembly（see Fig.1)
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Fig. 1
1 Lock ring
2 Lock washer
3 Helicoids
4 Shaft
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BONDING
1 General Description of Bonding

The purpose of bonding is to provide as much as possible an ideal electrical conductivity
between different parts on aircraft.
2 Connection of Contact Points
2.1 Surface pre-processing
Connection surface and structural surface of connecting the bonding jumpers should be
pre-processed as follows：
— Use solvent to remove the paint coating
— Aluminum and aluminum alloy surface should be slightly ground using emery paper
(320 # ), then shall be immediately covered with a coat of very thin paraffin oil
(mineral Vaseline AIR 3565 or compound Vaseline grease S G E 5085 or
OX-50-855 intermixture shall be applied on contact points).
— The anodizing treated surface should also be ground using emery paper.
—Screws, nuts and spring washers fixed on should be adequately conductive (for
example： they mast be made of cadmium plated or galvanized steel，having no any
insulation layers).
—The fastening connection obtained in such a way can provide a reliable contact
pressure，and automatically lock.
2.2 Electric lapping using rivets
— When assembling the anodization or paint protected parts，protective layers should be
removed in the following cases：
• Rivet holed used for various kinds of riveting
• Countersunk holes used for countersunk rivets
• Inner surface in dimple or skin at recess used for countersunk rivets.
— For all these rivets，rivet head matching surface should have no insulating protection or
clear off as shown below (see detail A in Fig.1) ( head diameter+2mm).
— Generally，spacing of electric connecting rivet should be 200mm，electric connection
rivets refer to unanodized aluminum alloy rivets.
— On the assembly of not exceeding 200mm，one earth point is enough.
— Example for riveting (see detail A in Fig.1).
2.3 Bonding using screw and bolt
— Matching surface of screws, nuts and washers should have no insulating protection or
clear as described below (washer or screw head diameter+2mm). The matching surface
of countersunk screw should have no insulating protection or clear off as shown in
detail B of Fig.1.
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— Generally， spacing of lap joints should be 200mm.

— On the assembly of not exceeding 200mm，one grounding point is enough.
— Lapped screw head or bolt head should be coated with a red mark so as to be easy in
the visual check.
— Bonding example of screw and bolt (see detail B in Fig.1- S/N 1，2，3，4，5，6，7).
2.4 Electric lapping using quick release fastener
Matching surface of DZUS or CAMLOC socket should have no insulating protection or
clear off as shown in detail A of Fig. 2 ( head diameter: +2mm) and for service
passageway，use quick release fastener for electric lapping instead of ground wire.
2.5 Electric bonding using ground wire (see detail B in Fig.2)
2.5.1 On thick part (S/N 1)
With help of a thread cut screw hole，use the cadmium plated steel screw and washer
for connection, and there is no need to clean the surface.
2.5.2 On thin part (S/N 2)
Carry out the connection by using screws and self-locking nut s.
2.5.3 On structural fixing part (S/N 3)
— It can be connected to the ground wire through a connecting plate which is fixed
with crew and nut or rivet.
— When the electric lapping is difficult on the assembly, use this kind of connection
method.
2.5.4 On circuit
— Electric wire clamp without protective layer (S/N 4)
— Use the electric wire clamp with protective measures (S/N 5)
Use a lap strip，overrun wire of bonding strip on the length shall be equal to strip width
+2mm
2.5.5 Under condition with earth wire not connected (S/N 6)
— Using cadmium plated connecting lug (1) installed on the fixing part (2) and
terminal strip on cable.
— It is used for electric tapping of replaceable or frequently removable assembly，and
the removable assembly generally includes connection lugs on cable and fixing
part .
— Fixing part within the range of longer than the bonding connection area and width of
2mm.
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Fig. 1
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Fig. 2
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BONDING METHOD
1 Bonding Method (See Fig.1)

a) Grinding and cleaning
— Use metal brush to grind the bonding area, clean it using non-greasy solution (i.e.
trichloroethylene).
b) Treatment
— The ground area should be applied with one coat of SGE 5085 Vaseline grease, or
AIR3565 or BRISSAL OX-50-855 mixture.
c) Connection
— Use bolt and washer for connection
d) Protection
— After proper of bonding element, on screw head, bonding jumpers and round area
grinding should be applied with one coat of DBLQ/6801green insulation paint.
Fig. 1
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BONDING ON METAL STRUCTURE AND HONEYCOMB PANELS
1 Bonding Point on Metal Structure

1.1 General (see detail A in Fig.1)
The bonding point of the shield cable connection and the general connection of part, that
should be comprised of4mm diameter steel bolt a proper length，aluminum bonding
washer and self-locking nut. Self-locking anchor nut can also be used at a place where the
accessibility is limited.
1.2 Operation procedure
When carrying out the connection，the structure in contact with bonding washer is not
required for fine finishing. It is required to re- protect the area, where the protective paint
was removed, in the perimeter around bonding point beyond washer bonding after the
final connection completed, and for the operation method, refer to the task card
20-02-07-401of this manual.
Precautions ： There must be absolutely no bonding points on the magnesium or
magnesium alloy structure.
2 Bonding Point on Honeycomb Panel or Shelf
2.1 General
In case electric appliance or radio equipment are installed on honeycomb panel or shelf，
it is necessary to provide the bonding of plate or shelf to aircraft structure.
2.2 Method
1) For area around bonding bolt，there must be no protective treatment before the bonding
jumper is connected.
2) For plate or shelf surface and rivet head，there must be no protective treatment before
riveting，so as to make sure the both surface of plate or shelf have a fine electric
contact.
3) After assembling bolts and bonding rivets，unprotected area should be re- protected, for
which refer to the method in the task card 20-02-07-401of this manual.
2.3 Bonding methods to be used
2.3.1 Bonding points are located on the edge of plate or shelf (see detail B in Fig.1)
Part 1-Bonding jumper
Part 2-4mm diameter steel bolt
Part 3-Bonding washer
Part 4-Spring washer
Part 5-Inserts
Part 6-Tapping rivet-2 pieces -3.2mm diameter (to ensure electric bonding between
plate surfaces).
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Part 7-Metal plate

Part 8-Honeycomb panel Part
2.3.2 Bonding points under certain honeycomb floor connection bolt (see detail C in Fig.1).
Bonding jumper shall be as close as possible to aircraft skeleton.
Part 1 - Bonding jumper
Part 2 - 4mm diameter steel bolt
Part 3 - Bonding washer
Fig. 1
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Part 6 Lap rivet-6 pieces -3.2mm diameter

Part 8 Honeycomb floor
2.3.3 At bonding point of any convenient plane on the plate (see Fig.2), bonding jumper
should be as short as possible.
Part 1- Bonding jumper
Part 2- 4mm diameter steel bolt
Part 3- Bonding washer
Part 4- Spring washer
Part 5- Bonding rivet-3 pieces -3.2mm diameter
Part 6- Inserts
Fig. 2
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BONDING PAINTING - 1318 B VARNISH

OR DBLQ-6801 GREEN INSULATION VARNISH
1 DUROUX 1318 B Varnish or DBLQ-6801 Green Insulation Varnish

1.1 General
Conventionally used DUROUX 1318 B insulation varnish or DBLQ-6801 is mainly a
kind of protective coating.
The is transparent varnish can be dried in the air, forming a protection film, heating to 60
℃ can speed up hardening of the film but can not strengthen its performance, the film
has perfect flexibility , and has good adhesion on all pre-degreased surfaces.
The dried and cured film is not sensitive to humidity. Its main characteristic is of high
insulativity (0.06mm thick film can insulate about 6,500V).
This characteristic is particularly distinct in the high frequency, and under these
conditions, “Skinning” can be prevented.
In addition, the dried varnish surface is water-proof, and the formation of water film can
be prevented under saturated atmosphere, and therefore, its insulativity can be maintained
even under extremely unfavorable atmospheric condition.
1.2 Scope：
This card specifies that 1318 B varnish or DBLQ-6801 varnish is to be used.
The normal dry time between two coats is 4hours, after 24hours, insulated coat will be
completely cured.
1.4 Operating procedure
1.4.1 Prior to applying varnish, use trichloroethylene or SCALP 725 solution to thoroughly
clean and degrease the surface. It is required to completely remove any Vaseline or
SGE 50 855 compounds that are left from the previous bonding procedure.
1.4.2 Apply 1318 B varnish or DBLQ-6801 varnish, the paint coat should be spread to
connecting point itself or bonding area by 4-5mm (i.e. the ground area previously used
for bonding).
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HYDROCARBON BASED CONDUCTING GREASE
1 General
This product is a hydrocarbon based conducting grease which is mixed by paraffin wax
hydrocarbon condensed mineral applied to conducting unit and antirust agent.
Caution: After operation, seal the container to keep from moisture.
2 Application
Hydrocarbon based conducting grease is used for antirust of metal components at aircraft
bonding point.
3 Operating Procedure
Use solution to clean or wipe metal surface at aircraft bonding point, after dried, all will be
coated with hydrocarbon based conducting grease.
Note: The standard for hydrocarbon based conducting grease is Q/SYK-3.3-86.
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INSTALLATION AND TIGHTENING UP

OF BEARING OR SELF-ALIGNING BEARING
1 Installation and Tightening Up of Bearing or Self-Aligning Bearing

1.1 Rules and regulations on relevant working area and equipment
— The workshop where bearings and self-aligning bearings are assembled and tightened
should be free from dust, moisture, metal chips or debris coming from supplementary
processes such as drilling, grinding and filing.
— Operators should wash clean and dry their hands to prevent hazards of various
corrosions.
— Cleaning process of parts should be carried out using approved articles. Soft brush or
hard substance (such as buttons, clips, metal chips,) free and lint free clean wiping rag
should be used. The articles used for leaning, insulating or other purposes should be
kept in their original packs, and should be used in accordance with preservation date
and storage temperature described in the relevant documents, on packing or present
documents.
1.2 Rules and regulations on relevant bearings or self-aligning bearings and braces
— Be sure bearings or self-aligning bearings are free from any foreign matters, their
rotation and driving moment are in conformity with current standards
— Unless otherwise specified on drawings, roughness degree of surface that contains
holes for bearing or self-aligning bearing should be 0.4.
— Unless otherwise specified in the Maintenance Manual or Standard Practices Manual,
protective treatment performed in the holes of braces must be suitable for basic
material. They should be：
• Light alloy should be treated using Alodine.
• Magnesium and magnesium alloy should be pickled with chromate acid.
• Stainless steel and titanium has no need for protection treatment.
— Check braces that their holes should be free form cracks, scratches or nay foreign
matters.
— Grinding the outer race outer edges and inner race inner edges of bearings or
self-aligning bearings to be assembled. Prior to installation, bearing or self-aligning
bearing 的 surface of bearings or self-aligning bearings and brace fitting surface should
be thoroughly degreased using lint free clean wiper dipped with appropriate liquid.
— fitting surface should be isolated using M3-1 sealing grease or equivalent liquid.
— If present grease of bearing or self-aligning bearing is to be completely removed, then
this process should be carried out before next process, so as to minimize the contact of
the part with outside air to minimum extent. The new greasing process should be done
as soon as possible using products required by this kind of bearings or AIR 4225
grease if not specified. The run-out amount of bearing or self-aligning bearing and
brace, if any, should be identified prior to assembling, so that the main center line of
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bearing or self-aligning bearing can be aligned with the center line of brace hole.
However, this run-out amount should not exceed the amount specified in the
Maintenance Manual or Repair Manual.
For convenience of assembling, external members can be heated in accordance with Para
1.3 of 20-02-05-403 in the Standard Practices Manual, but any other treatments are strictly
prohibited. After assembling, check the position of bearing or self-aligning bearing, to
ensure it is properly tightened. Check rotation and driving moment in accordance with
bearing types of 20-02-08-601 in the Standard Practices Manual.
1.3 Other rules and regulations
Bearing or self-aligning bearing should be packed and preserved as delivered in the
manufacturer, and stored in a dry room, and depreservation can be made only before
installation.
The tools should be clean and in a good work state, it is prohibited to use the tools for
operations other than the designed purpose.
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REMOVAL/INSTALLATION AND SLOT OR SPHERICAL TIGHTENING

UP OF BEARING OR SELF-ALIGNING BEARING
1 Removal/Installation and Slot or Spherical Tightening of Bearing or Self-Aligning

Bearing
1.1 Taking out (see detail A in Fig.1)
With a supporting part on spacer block(3)，use the punching head (1) to load the outer
race of bearing or self-aligning bearing from the tightened opposite side，to take out the
bearing and self-aligning bearing.
1.2 Inspection prior to assembling new bearing
— Before installing a new bearing，remove completely flash that is left in the hole from
the first tightening-up.
— Conduct a proper partial protective machining and repair.
— Make sure there is no scratches and depositions in hole，and it is required to take the
requirement of document for installation into account，and its sizes should be in
compliance with installation requirement for a new part.
1.2.1 Tightening-up of undiscarded supporting part
— In the second tightening-up，it is required to distribute new indentations in between
indentations of the last tightening-up (see detail Bin Fig.1).
— This procedure only can be carried out once，and the same part is at most allowed to
be tightened twice.
— Carry out tightening-up (1)，to ensure the indentation relative to indentation (2) of
first tightening-up is shifted by 30°.
1.2.2 Installation of bearing or self-aligning bearing on supporting part (see detail C in Fig.1)
— In installation of bearing or self-aligning bearing(1), it is required to apply a
pressure，use tools［punching head (2)，spacer block (3)］to press，and at the same
time, it shall be in compliance with description of assembling and relative position
of the part.
— Press in the load required by bearing as per data given in the Table below.
— Check the position of bearing or self-aligning bearing, ensure bearing will not move
under action of tightening load.
— As long as there is no any factor limitation or requirement，and if necessary, take out
the bearing or self-aligning bearing from the supporting part，turn it through 90°
relative its original position, and fit it into supporting part from the opposite side of
the first installation. An axial load can be applied from the fitting surface to the
outer race of bearing for removal.
Prior to assembling，check if the matching surface is damaged (cracks, scratches, metal
chips, deformation) and the insulation between different materials sufficient or not.
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1.2.3 Tightening of bearing or self-aligning bearing on supporting part (see Fig.2 and Fig.3)
Generally, the slot type tightening is applicable to steel or aluminum alloy parts，and
spherical tightening is applicable t magnesium alloy parts.
Tightening is carried out on press machine，the forces of press machine given in Table1
and Table 2 are for reference.
Structure of tightening tools is given in Fig.3 and Fig.2, and these tools must ensure
tightening-up relative to bearing or self-aligning bearing shall have a proper
concentricity. If both sides of bearing or self-aligning bearing are required to be
tightened up, the two-way tool fit with spring can be used to simultaneously to perform
this procedure, so that pressure of two sides can be balanced.
After tightening-up，check：
—Depth indentation
—Position of bearing or self-aligning bearing.
— If there are cracks
— Rotating and rotating moment (if it is specified in the maintenance or repair
document).
Carry out protective treatment as specified in the document.
Apply lubricating grease bearing or self-aligning bearing as specified in the drawing，
and if it is not specified in the drawing, then apply grease AIR4225.
Fig. 1
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Table 1 Load on Bearing or Self-Aligning Bearing and Tightening-Up
Bearing or self-aligning
bearing 10 12 14 15 16 19 21 22 24 26
Outside Diameter
32 35 39 40 42 45 51 52 56 60
Pressing in load
- - - - - - - - - -
10N
42 45 49 50 52 57 61 63 66 70
Tightening-up 1880 2000 2170 2200 2340 2600 2770 2850 3020 3200
load Steel - - - - - - - - - -
2180 2300 2470 2560 2640 2900 3070 3150 3320 3500
580 900 1070 1070 1240 1500 1670 1750 1930 2100
2024 - - - - - - - - - -
10N 1180 1200 1370 1370 1540 1800 1970 2050 2230 2400
Table 2 Load on Bearing or Self-Aligning Bearing and Tightening-Up
Bearing or self-aligning
bearing 28 30 32 35 37 40 45 50 55
Outside Diameter
63 67 70 76 79 85 92 103 115
Pressing in load
- - - - - - - - -
10N
73 77 80 86 89 95 102 113 125
3370 3540 3710 3960 4140 4400 4920 5300 5750
Steel - - - - - - - - -
Tightening-up load 3670 3840 4010 4260 4440 4700 5120 5600 6050
10N 2270 2440 2610 2870 3060 3300 3740 4200 4600
2024 - - - - - - - - -
2570 2740 2910 3170 3340 3600 4040 4500 4900
Note:
1) If diameter of installed bearing is not given in the Table, the draw a curve for ratio of
bearing diameter to load，from which the load value required by the diameter can be
calculated.
2) When the required moment is the same as moment necessary for tightening-up, and
rotating and rotating moment must be low，then pressing-in load is effective for the
whole situation.
3) In case the rotating and rotating moment must be low, the tightening-up load is only
effective for the slot type tightening-up.
4) Carry out all checks as specified in20-02-08-601 in Standard Practices Manual.
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Fig. 2
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Fig. 3
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— If it is specified in Maintenance Manual or Repair Manual，check the rotating and

rotating moment.
— Carry out all checks specified in20-02-08-601 in Standard Practices Manual.
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REMOVAL，INSTALLATION AND CLAMPING OF

T
BEARING OR SELF-ALIGNING BEARING

T
WITH TRANSITION LINER AND INSERT WASHER

T
1 Removal, Installation and Clamping of Bearing or Self-Aligning Bearing with

Transition Liner and Insert Washer
1.1 Removal and replacement of bearing or self-aligning bearing (see detail A in Fig.1)
— Use ream tools［including frame (1)，adjustable tool blade (2)，and pilot (3) with
diameter equal to the bearing inside diameter］to remove a section of transition liner
folded on the washer.
— Take down the washer
— Apply axial load transition liner from the other machined end， push out the bearing or
self-aligning bearing of having transition liner.
Note: The accepted parts are required to be reinstalled as specified in Paras. 1.2 and 1.3
of this chapter.
1.2 Preparation of parts (see detail B inFig.1)
Unless otherwise specified in the document，the surface roughness of transition liner (5)
should be 0.8μm on bent surface and 0.4μm in the bore and outer circle surface.
Unless special description is given in the maintenance and repair document，the average
surface roughness of inserted washer should be 0.8μ.
Unless otherwise specified in the maintenance and repair document, liner (5) and
washer(4) shall be surface treated as follows：
Light alloy shall be treated with Alodine.
Cadmium plating shall be made on low alloy steel.
Stainless steel has no need for protection.
Note: detail B in Fig.1 indicates installation of bearing before and after bending.
1.3 Assembling bearing or self-aligning bearing
The assembling shall be carried out in two steps：
— Fit the bearing or self-aligning bearing into transition liner and bend the liner.
— Put bearing or self-aligning bearing together with transition liner into the supporting
part.
1.3.1 Fit bearing or self-aligning bearing into transition liner and bending the liner (see detail
A in Fig.2，and detail A in Fig.3)
— Carry out assembling on press machine using tools ， to ensure bearing or
self-aligning bearing in liner will be correctly located, and be in compliance with
general assembling requirements in Maintenance Manual or Repair Manual.
— It is necessary to use the fixture to clamp the outside of liner (see Fig.3)，in order to
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prevent any deformation while assembling and bending. Check if the bearing or
self-aligning bearing are correctly located on the internal shoulder of the liner and
check rotating and rotating moment.
— Bending shall be carried out in two steps：
The first and last procedures shall be performed on a driller or lathe, and its rotating
speed is approximately 10-15m/min, i.e.：
• 20 -35mm bending diameter is 150r/min
• 35-60mm bending diameter is 100r/min
— Apply molybdenum disulphide lubricating grease to the area to be bent (e.g.:
molybdenum disulphide lubricant G type lubricating grease). If self-aligning
bearing is automatically lubricated，then use tallow, and after that use “baltane” for
cleaning .
— Upon completion of bending, clean the assembly so as to remove molybdenum
disulphide lubricating grease.
— Check if the bent is integrated，to ensure bent convex edge is free form scratches,
cracks and buckling.
— Repair the machined surface of bent convex edge as specified in the drawing.
— If bearing or self-aligning bearing with liner can not be immediately fitted into
supporting part，which should be applied with lubricating grease or grease AIR4225
as specified in the document. Self-lubricating self-aligning bearing shall be sealed
using oil.
— If it is specified in the maintenance or repair document, check rotating and rotating
moment.
— Put the assembly into a sealed polyethylene transparent pack for storage.
1.3.2 Install bearing or self-aligning bearing with liner and bending to supporting part (see
detail B inFig.2, detail B in Fig.3)
— Carry out the assembling on a press machine，and pay attention to correct location of
different parts and compliance with general assembling requirements in
Maintenance Manual or Repair Manual.
— It is required to make sure convex edge of liner against bearing，and check rotating
and rotating moment.
— Put in the washer，and carry out bending procedure on the low speed driller or lathe.
As specified in Para. 1.3.1 of this chapter，use molybdenum disulphide lubricating
grease to lubricate the tools. If it is a self-lubricating self-aligning bearing，then use
tallow, and after that use “bal-tane” for cleaning.
— With all tallow removed, check if the bending is correct. The bent area must be
correctly fit，and be free form scratches, cracks and buckling.
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— Trim the machined surface of bent convex edge as specified in the drawing.
—Apply tallow to bearing or self-aligning bearing as specified in the drawing. If it is
not specified in the drawing，grease AIR4225 can be used. The self-lubricating
self-aligning bearing has no need to be applied with tallow.
Fig. 1
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Fig. 2
Fig. 3
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REMOVAL, ASSEMBLING AND ROLLING

TIGHTENING-UPOF ARC RECESS BEARING
1 Removal, Assembling and Rolling Tightening-Up of Arc Recess Bearing

1.1 General
1.1.1 Scope（see detail A in Fig.1)
Fig. 1
The assembling and tightening method of ADR made metric joint self-aligning bearing
is specified.
Note:
— On circle of 25％，the allowable maximum clearance is 0.2mm. The tightening
surface should be free from scratches and adhered substances.
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— Relevant bearings before tightening-up (1) and after tightening-up (2) are given in
detail A.
1.1.2 Characteristics of shell (see detail B in Fig.1)
—Unless otherwise specified in Maintenance Manual or Repair Manual.
—ADR self-aligning bearing should be chamfered as specified in Table below.
• Width of shell (size B) should be equal to the width of self-aligning bearing outer
race.
• Determine the dimensions of ADR self-aligning bearing to be used in reference to the
table below.
Chamfer 45°
ADR Self-Aligning Bearing 0 0
+0.1
D B P e
C
Model -0.2 -0.2
-0.1
RE 5R 14 5.5 0.7 4.6 0.5
RE 6R 16 6.5 0.7 5.6 0.5
RL 6R 16 8.5 0.7 7.6 0.5
RL 8R 18 8 0.7 7.1 0.5
RE 10R 21 8 0.9 6.7 0.7
RL 10R 21 10 0.9 8.7 0.7
RE 12R 25 10 0.9 8.7 0.7
RL 12R 26 13 0.9 11.7 0.7
RL 15R 29 13.5 0.9 12.2 0.7
RL 17R 30 14.5 0.9 132 0.7
RL 20R 35 16 0.9 13.7 1.6
RL 22R 40 18 1.4 15.7 1.6
RE 25R 45 20 1.4 17.7 1.6
RL 25R 54 26 1.4 23.7 1.6
1.2 Removal of rolled tightening-up self-aligning bearing

— Use ream tools to remove the metal of rolled self-aligning bearing，pay attention not to
damage the shell.
— This procedure shall be performed only on one side
— On machined side of bearing outer race，press the bearing outer race along shaft，to
push self-aligning bearing out of the shell.
1.3 Assembling and tightening (see detail A in Fig.1 & Fig.2)
1.3.1 Assembling
Use the shell to match with each self-aligning bearing，so as to obtain a fit of 1-10μm，
or use the data specified in Maintenance Manual or Repair Manual.
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Fig. 2
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Refer to 20-02-05-403 in Standard Practices Manual，and use the press machine for
assembling.
If there is requirement in Maintenance Manual or Repair Manual, assemble the part to
their corresponding position，and after assembling，it is required to make sure to have
sufficient allowance, and check rotating and rotating moment，to make sure that the
allowance has no adverse effect on them.
1.3.2 (see Fig.2)
— This procedure shall be carried out on the sensitive driller，or if required，use the
tools specified in Fig.2 to perform on machine.
— Rotating speed is approximately 10-15m/min，in fact it is equal to：
• For 20-35mm tightening-up diameter，it is 150r/min.
— The tightening-up groove shall be applied with sufficient molybdenum disulphide
lubricating grease (e.g.: molybdenum disulphide lubricant G lubricating grease).
When using self-lubricating self-aligning bearing，do not use the lubricating grease.
—At first, tighten one side.
— Turn over the part，completely tighten up the second surface.
—Turn over the part，completely tighten up the first t surface.
— Clean parts to ensure tightening is correct (there should be no clearance between
tightening-up area and shell chamber).
1.3.3 Post tightening inspection
— Check that the tightened area is free from cracks, scratches and foreign matters, and
trim the machined surface as specified in Maintenance Manual or Repair Manual.
— Unless otherwise specified, use the lubricating grease specified in Maintenance
Manual or Repair Manual to apply to self-aligning bearing. If there is no indication，
then use grease AIR4225, and when self-land lubricating self-aligning bearing is
used，do not apply the lubricating grease.
— It is required to check the rotating and rotating moment as required in 20-02-08-601
in Maintenance Manual.
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REPLACEMENT OF UNLUBRICATED “DU” WEAR RESISTANT LINER
1 Replacement of Unlubricated “DU” Wear Resistant Liner

— “DU” is a kind of high performance composite abrasion-resistant material.
— Although it is not a kind of self-lubricating material，no lubricating is needed when it
is used however, available lubricant is also harmless.
— Composition：
• Surface layer: 0.025mm thick (1).
• Porous layer or tin bronze mid layer (2).
• Steel jacket (3) is etched tined steel plate.
1.2 Assembling of “DU” liner (see detail B in Fig.1)
— “DU” liner is a thin-walled liner, made by rolling the rear end and welding, and it is
delivered after calibration.
— Remachining in hole is not allowed.
— If bore diameter of the seat and diameter of shaft are machined according to sizes
given in Repair Manual or Maintenance Manual (see standard “DU” liner in Table
below )，then the matching naturally is correct.
— Use the guidance mandrel made as per Fig.1 to correctly assembling the liner.
— Machining：
• In all cases，damage to untrimmable abrasion resistant surface made of “DU” material
shall be avoided.
• When machining is conducted in the steel material area where the metal chip is
produced, plastic tape or rubber plug should be used to properly protect the “DU”
surface.
Note: For “DU” liner，temperature never exceed -200-327℃.
1.2.1 Use of assembling tools
a) Prior to assembling，check:
• Diameter “C” of guidance mandrel is 0-0.030 smaller than the diameter “D” of
“DU” liner (2).
• Apply a thin coat of lubricating grease to liner (2).
b) during assembling of liner (2)，check ：
• Liner (2) completely in compliance with hole of seat (3).
c) After fitting the liner (2) into seat (3)，check:
• A small chamfer (20°) shall be provided on guidance mandrel (1) and seat (3), o as
to facilitate assembling of the liner.
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1.3 Table for standard sizes of “DU” liner

Bore Diameter & Tolerance Diameter & Tolerance of
No。
of Seat Shaft
MB.06.06.DU 8.H6.J7 6.h6.h8
MB.06.10.DU 8.H6.J7 6.h6.h8
MB.08.08.DU 10.H6.J7 8.h6.h8
MB.08.12.DU 10.H6.J7 8.h6.h8
MB.10.10.DU 12.H6.J7 10.h6.h8
MB.10.15.DU 12.H6.J7 10.h6.h8
MB.10.20.DU 12.H6.J7 10.h6.h8
MB.12.15.DU 14.H6.J7 12.h6.h8
MB.12.20.DU 14.H6.J7 12.h6.h8
MB.14.15.DU 16.H6.J7 14.h6.h8
MB.14.20.DU 16.H6.J7 14.h6.h8
MB.15.15.DU 17.H6.J7 15.h6.h8
MB.15.15.DU 17.H6.J7 15.h6.h8
MB.16.15.DU 18.H6.J7.H7 16.h6.h8
MB.16.20.DU 18.H6.J7.H7 16.h6.h8
MB.16.25.DU 18.H6.J7.H7 16.h6.h8
MB.18.15.DU 20.H6.J7.H7 18.h6.h8
MB.18.20.DU 20.H6.J7.H7 18.h6.h8
MB.18.25.DU 20.H6.J7.H7 18.h6.h8
MB.20.15.DU 23.H6.J7.H7 20.h6.h8
MB.20.25.DU 23.H6.J7.H7 20.h6.h8
MB.20.30.DU 23.H6.J7.H7 20.h6.h8
MB.22.15.DU 25.H6.J7.H7 22.h6.h8
MB.22.20.DU 25.H6.J7.H7 22.h6.h8
MB.22.25.DU 25.H6.J7.H7 22.h6.h8
MB.24.15.DU 27.H6.J7.H7 24.h6.h8
MB.24.20.DU 27.H6.J7.H7 24.h6.h8
MB.24.25.DU 27.H6.J7.H7 24.h6.h8
MB.24.30.DU 27.H6.J7.H7 24.h6.h8
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No。
of Seat Shaft
MB.25.15.DU 28.H6.J7.H7 25.h6.h8
MB.25.25.DU 28.H6.J7.H7 25.h6.h8
MB.25.30.DU 28.H6.J7.H7 25.h6.h8
MB.30.20.DU 34.H6.J7.H7 30.h6.h8
MB.30.30.DU 34.H6.J7.H7 30.h6.h8
MB.30.40.DU 34.H6.J7.H7 30.h6.h8
MB.35.20.DU 39.H6.J7.H7 35.h6.h8
MB.35.30.DU 39.H6.J7.H7 35.h6，h8
MB.35.50.DU 39.H6.J7.H7 35.h6.h8
MB.40.20.DU 44.H6.J7.H7 40.h6.h8
MB.40.30.DU 44.H6.J7.H7 40.h6.h8
MB.40.50.DU 44.H6.J7.H7 40.h6.h8
MB.45.30.DU 50.H6.J7.H7 45.h6.h8
MB.45.50.DU 50.H6.J7.H7 45.h6.h8
MB.50.40.DU 55.H6.J7.H7 50.h6.h8
MB.50.60.DU 55.H6.J7.H7 50.h6.h8
MB.55.40.DU 60.H7.H8 55.f7.h7
MB.55.60.DU 60.H7.H8 55.f7.h7
MB.60.40.DU 65.H7.H8 60.f7.h7
MB.60.70.DU 65.H7.H8 60.f7.h7
MB.65.50.DU 70.H7.H8 65.f7.h7
MB.65.70.DU 70.H7.H8 65.f7.h7
MB.70.50.DU 75.H7.H8 70.f7.h7
MB.70.70.DU 75.H7.H8 70.f7.h7
MB.75.60.DU 80.H7.H8 75.f7.h7
MB.75.80 DU 80.H7.H8 75.f7.h7
MB.80.60.DU 85.H7.H8 80.f7.h7
MB.80.100.DU 85.H7.H8 80.f7.h7
MB.85.60.DU 90.H7.H8 85.17.h7
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No。
of Seat Shaft
MB.85.100.DU 90.H7.H8 85.f7.h7
MB.90.60.DU 97.H7.H8 90.f7.h7
MB.90.100.DU 97.H7.H8 90.f7.h7
MB.95.60.DU 100.H7.H8 95.f7.h7
MB.95.100.DU 100.H7.H8 95.f7.h7
MB.100.60.DU 105.H7.H8 100.f7.h7
MB.100.115.DU 105.H7.H8 100.f7.h7
MB.105.60.DU 110.H7.H8 105.f7.h7
MB.105.115.DU 110.H7.H8 105.f7.h7
MB.110.60.DU 115.H7.H8 110.f7.h7
MB.110.115.DU 115.H7.H8 110.f7.h7
Note: Number denotes the main dimensions of “DU” liner.

— 2 or 3 digits of the first group denote the nominal diameter of liner.
—2 or 3 digits of the second group denote the length of liner.
For example：
MB.24.25.DU
24= Inner diameter of liner
25= Length of liner
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Fig. 1
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REPLACEMENT OF ROSAN LINER AND STUD
1 Replacement ROSAN Liner and Stud (see Fig.1 and Fig.2)

1.1 General
a) Two kinds of installation mode
— Liner (1) allows installation of plain stud (2) (see detail a in Fig.1).
— Stud (3) can be directly fitted into the supporting part (see detail b in Fig.1).
— Both installation modes use the same kind of lock ring (4). It is required to make the
inner tooth of lock ring be engaged with outer tooth liner or stud installation ring，
outer tooth of lock ring should be pressed into supporting part body to prevent liner
or stud from rotating.
b) Installation chart for ROSAN liner and stud
Diameter A +0.08 +0.7

Diameter H Size P
Size of liner (metric Dia. G Size
(hole dia.) drill (Min. )
thread) 0 0
050 8×125 9.5 6.6 3.6 10.4
060 10×1.5 11.09 8.4 4 11
080 12×1.75 13.08 10.1 4.4 12.6
100 14×2 15.06 11.8 4.4 14.5
120 18×2.5 22.2 15.3 5.1 16.5
Diameter A +0.08 +0.7

Diameter H Size P
Size of stud (Metric Dia. G Size
(hole dia.) drill (Min. )
thread) 0 0
050 6×1 8.33 4.9 2.8 16
060 8×125 9.52 5.6 3.6 19
080 10×1.5 11.09 8.4 4 24
100 12×1.75 15.06 10.1 4.4 32
120 14×2 18.64 11.8 4.8 35
1.2 Removal of liner or stud

1.2.1 Liner
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1) Drill out the internal toothed surface of lock ring (4)（see detail C in Fig.1), drill to
the first turn of thread of liner (1). Drilling speed：300—700r/min.
2) Use a stud removal tool (5) for removing or a square bar to take out the liner (see
detail a in Fig.1). Take down liner (1)，extract the remaining portion of the lock
ring(4).
3) Use a pointed punching head to take out the remaining portion of the lock ring (4)
(see detail e in Fig.1).
1.2.2 Stud
1) It is recommended to use a special ROSAN hollow milling cutter to mill external
tooth of stud and internal tooth of lock ring (4). When it is milled to the shoulder，
that is to say reaching the first turn thread of stud (see detail f in Fig.2）
2) Based on the condition of stud，use one of following methods to take out the stud
(3)(see detail f in Fig.2).
— Use the stud spanner to screw off the stud.
— Cut the stud，drill hole and remove the stud like removal of liner (4).
3) Use a pointed punching head to take out the remaining portion of the lock ring (see
detail h in Fig.2).
1.3 Installation of liner and stud
Note:
— When replacing the ROSAN) part，use the same sized liner, stud or lock ring.
— hen inserting the lock ring，ensure the internal tooth of lock ring is engaged with
external tooth of liner or stud，and external tooth of lock ring is engaged with
tooth mark of previously inserted supporting part.
1) If necessary，a screwdriver in consistence with liner or stud to be installed can be used
to clean the threaded hole of supporting part. French made ROSAN parts use I.S.O
standard thread (see Table).
2) Installation of liner or thread（see detail e in Fig.2).
— A first, apply seal grease M3-1 to the surface that is in contact with supporting part.
— Use an appropriate ROSAN tool (7) to install the liner (1) or stud (3).
3) Installation of lock ring
Use a hammer to slightly hit or use press machine and flat or tubular spacer block or
ROSAN tool to install the lock ring (see detail K, 1 in Fig.2).
Note: the flat spacer block is required to have two shoulders.
1.4 Inspection
Check position of lock ring (see detail a, b in Fig.1).
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Fig. 1
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Fig. 2
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REPLACEMENT OF INSERTS IN SANDWICH PLATE
1 Replacement of Inserts in Sandwich Plate (Metal and Laminated Honeycomb)

1.1 General
Inserted pieces，connecting parts, support parts and lock liner need to be carefully
assembled only by skilled workers.
1.1.1 Equipment required
AV 121 epoxy resin (DHS 268.112.20)

— No. 9 mixture AY 103 epoxy resin
Curing agent HY 951
Micro-balloon (BAKELITE plastic) BJOA0930
— Hot air gun

— Injector used to fill mixture or SEMCO type spray gun with detachable plastic
C.250 tube and spray nozzle.
— Drilling - broaching tool- edge knocking tool
1.2 Operating procedure
1.2.1 Extracting (see detail A in Fig.1)
1.2.1.1 Extracting dislocated inserted piece
Fit the extracting tools (2) together with screw (3) used for disassembling on a
plate (1)，and use hot air (4) to heat micro-balloon filler, and it is required to avoid
any damages to glued surface . During heating，in order to take out the inserted
piece (6)from slot，and y a pulling force to screw by screwing in nut(5).
1.2.1.2 Extraction of screw broken in inserted piece with thread damaged（see detail B in
Fig.1)
Around the shell，on upper convex edge (7) of inserted piece (6) drill 2.5 or 3mm
diameter orifice.
Remove the convex edge，try as much as possible to drill the micro-ballon for
fixing insert to pieces using a drill bit. Use (4) heat micro-ballon area (8) and use
the pliers to take out residual inserted pieces.
1.2.2 Preparation for locating the inserted piece (see detail C in Fig.1)
1.2.2.1 Preparation for the notch of inserted piece
— The position of inserted piece (6) can be determined according to the sizes
given in the Repair Manual or drawing，drill a guide hole with diameter of 4mm
on the skin.
— Use the locating pin inserted in the guide hole of 4mm diameter to guide the
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drill bit of the drill，and drill a hole, of which the diameter exceeds the inserted
piece diameter by +0.2mm on the upper skin (14) .
— Use the tool (9) to remove the honeycomb material (15) sandwiched between
two layers of skin (13-14)，machine a notch as per the diameter in compliance
with Repair Manual and drawing.
1.3 Installation of parts (inserted piece, fastener, and liner)
1.3.1 Installation of inserted piece (see detail C in Fig.1)
— Once the notch of the inserted piece is properly prepared and cleaned, install
inserted piece (6) according to the following methods：
— Take one standard adhesive disk in compliance with the inserted piece，and remove
the protective paper.
Fig. 1
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— Position adhesive disk (16) on guiding device, coincide stud bolt with hole, turn the
part outward, then insert the stud bolt into plug-in unit.
— Firmly press down the part and remove the guiding device, with the disk adhered to the
surface of plate, locate the plug-in unit in notch of honeycomb, so plug-in unit (6)
can be flush with plate (1), threads can be protected properly with clear binder (17).
— Fill the notch via filling pipe (10) till mixture appears in exhaust port (11).
Note: It is recommended that a settling time of 20-30min is required before a small
amount of fresh mixture is added.
— Let the mixture be cured under 20℃ for 15h, and then remove adhesive disk.
1.3.2 Installation of fasteners and bushings
There is no disk, filling pipe or exhaust port connected in these parts, the installation of
the inserts should be conducted in accordance with the following method：
— Drill two relative holes with diameter of 3mm at the place about 2mm from well
prepared notch on the upper skin , original honeycomb notch diameter between two
layers of skin diameter is as per requirements of drawing.
— On the heat-resistant Plexiglas sheet with thickness of 2-3mm and a little larger than
the part to be fixed, drill two holes with diameter of 5 mm which correspond to
those two holes drilled on the upper skin .
— Adhere a tape (PERMACEL No. 750) with adhesive on both sides to between
heat-resistant Plexiglas sheet and bushing or fastener, and firmly compress it.
— Position the bushing or fasteners into the notch, and use adhesive to the stick
heat-resistant Plexiglas on the skin.
— Fill the notch with No.9 mixture.
— After mixture cured for 15h under temperature of 20℃, remove the Plexiglas sheet
with adhesive tape.
Note: In case the plate has several of fasteners or bushings of plug-in units, it is
recommended that when pouring the mixture, identify all parts of the work piece
with marks to prevent any possible careless, and if both skins have such work piece,
then it is required to wait for the mixture on one side being complexly cured
(approximately 15h under temperature of 20℃) before turning over the plate
1.4 Pull-out strength test (see detail D in Fig.1)
— The test is to be carried out in accordance with principles as follows:
— With following load values applied and read out from spring balance (1), 4mm
diameter is 200N
5 mm and 8mm diameter is 300N
Fastener and socket is 500N
Note: These load values are much lower than the load values required to pull out the
plug-in unit, and they are allowed to check strength of plug-in unit in a notch under
such condition that no deformation of plate will be caused.
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1.5 X-ray inspection

X-ray inspection criteria：The pull-out strength test is required to be conducted if there is
one or a few of air bubbles present, and test results may determine if it is required to
replace plug-in unit.
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REPAIR OF ENGINE INTAKE
1 Installation of Vortex Tube Port and Conic Outflow Nozzle on Engine Intake Duct
Strainer
1.1 General
— Full effective and correct installation of the strainer assembly can apparently increase
service life of engine.
— In the most of time, damages to air inlet duct strainer sheet are caused by displacement
or loss of conic outflow nozzle (2) and vortex tube (1) from the support plate (7) and
upper support plate (3).
1.2 Main damage forms that may be found on engine intake duct (see Fig.1).
1) Displacement of vortex tube (1) (see detail a in Fig.1). Repair tool kit is QR 1063(10).
2) Loss of vortex tube (1) (see detail b in Fig.1). Repair tool kit is QR 1063(11).
3) Loss and/or damage of vortex tube (1) and conic outflow nozzle (2) (see detail C in
Fig.1). Repair tool kit is QR 1062(12-13).
— If any defects are found in routine maintenance inspection, it is required that：
• Check and finding out defective part according to the above damage types.
• Repair or replace parts in accordance with task cards 20-02-08-408 and 20-02-08-409 in
the Standard Practices Manual.
Fig. 1
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INSTALLATION OF ENGINE INTAKE STRAINER VORTEX TUBE AND

CONIC OUTFLOW NOZZLE
1 Installation of Engine Intake Strainer Vortex Tube and Conic Outflow Nozzle
— Vortex tube (1) and conic outflow spray nozzle (2) is made of polypropylene and fiber
glass.
— The tube is fixed on the upper plate (3) of box member, which has a centrifugal effect
on air inlet flow (4)，that is, to separate the air inlet flow into clean air (6) and polluted
air (5) (sand, snow etc.).
— Conic outflow nozzle (2) is fixed on the lower plate (7) of box member, which
distributes clean air to engines.
2.1 Special tools
— Packaging tool 703A.93.0900(A) including：
• One tool kit
• One set of 220/24V-50W welding equipment.
• One soldering iron
• One die No.1.
• One die No.2.
• One pipe support of soldering iron.
• One insert tool for vortex tube (to be locally made) ( A in Fig.1B-a)
—Insertion tool of conic outflow nozzle (to be locally made) (C in Fig.2A)
3.1 Installation of vortex tube
— Use tool (A) to insert in the vortex tube.
— Use tool (B) for packaging.
Note: The details a,b,c,d,e,f in Fig.1B shows the installation of vortex tube.
— The details a,b,c shows the inserting procedure.
— The details d,e,f shows the packaging procedure.
— Several tubes can be packaged at one time by using the same method and parameters.
— Use an adjustable heating plate.
— Heat the end fitting to 105-115℃.
— Safety measures.
• It is not allowed to exceed the specified temperature, because material tends to shrink at
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the time of heating.

• It is not allowed to repack, hence the d,e,f procedures in Fig.1 should be completed in
one stroke.
3.2 Installation of conic outflow nozzle（see detail A in Fig.2)
— Use tool C shown in Fig.2A to insert the conic outflow nozzle (2) into the lower plate
(7).
— Heating can be made in hot water (70-80℃)，to enable material to have flexibility
which is easily to be inserted .
Fig. 2
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4 Note
— The correct installation of vortex tube (1) and conic outflow nozzle (2) installation
depends on condition of their flanges. Defect visible on flange indicates the packaging
strength is insufficient. Therefore, such defective tube and nozzle must be discarded and
replaced.
5 Check for Correct Installation of Vortex Tube (1) and Conic Outflow Nozzle (2) (See
detail B-a and detail A in Fig.2)
— Visually check insertion and packaging condition of vortex tube and conic outflow
nozzle.
— In the center area, use a pin to apply a load of 60N and visually check packaging strength
of defected vortex tube.
Precautions：It is prohibited to use the check procedure described in detail B-b in
Fig.2.
Fig. 2
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INSTALLATION AND BONDING OF ENGINE INTAKE STRAINER

VORTEX TUBE AND CONIC OUTFLOW NOZZLE
1 Installation and Bonding of Engine Intake Strainer Vortex Tube and Conic Outflow
Nozzle
1.1 General
Refer to task card 20-02-08-408 in the Standard Practices Manual.
2.1 Standard tools
— Scraping cutter A.
— Organic glass cutter or hard wood cutter B.
2.2 Special tools
— Vortex tube inserting tool C (A in Fig.1a)
— Conic outflow jet pipe inserting tool D. (C in Fig.1b ) (locally made).
2.3 Material
— Ketone
— Adhesives ROSTIK 1400.
— Sealing compound PR 1321A or B
2.4 Applicable documents
Task card 20-06-01-310 in Standard Practices Manual.
Task card 20-05-01-203.
3.1 Surface pre-processing
— Use tool B to remove any adhesive traces from upper and lower supporting plate (3)
and (7).
— Use MEK (ketone) for cleaning.
3.2 Bonding vortex tube (1) and conic outflow nozzle (2) part.
3.2.1 Installation of conic outflow nozzle
— Use tool A to apply one layer of adhesives to groove in conic outflow nozzle (2).
—Use tool C to insert in conic outflow nozzle.
— Clear off any surplus adhesives.
3.2.2 Installation of vortex tube
— Carry out the whole procedure above mentioned, and use tool A to properly install
the vortex tube on supporting plate (3).
— Clear off any surplus adhesives.
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4 Check the Correct Installation Condition of Vortex Tube (1) and Conic Outflow Nozzle
(2).
—Refer to Section 5 of task card 20-02-08-408 in this Standard Practices Manual
Fig. 1
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CHECK BEFORE, AFTER ASSEMBLING AND TIGHTENING OF

BEARING
1 Checks before, after Assembling and Tightening of Slot or Spherical of Bearing &
Self-Aligning Bearing
1.1 Checks Before assembling
1.1.1 Hole of shell
1.1.1.1 Surface roughness
The holes should be smooth，if there is no other specification in drawing or the
Repair Manual，the surface roughness value Ra shall not be more than 0.4μm. It is
not allowed to have metal cracks, spalling，adhesions and circular or lateral
scratches.
1.1.1.2 Dimensions and tolerance
As specified in the Repair Manual.
It is recommended to use micrometer with reading in measurement instead of insert
gauge，because the insert gauge is unable to accurately indicate defects such as
ellipse, conic holes, shear marks.
1.1.1.3 Surface treatment
The shell shall be surface treated as the basic part，and in order to ensure the
tolerance required by assembling, the surface treatment of remachined hole should
carried out as specified in the Repair Manual.
1.2 Requirement for assembling
a) Before assembling bearing or self-aligning bearing，it is required to check for metal
grain or other foreign matters.
b) Check if the edges of bearing internal and outer races have any rough points or sharp
edge. If such defects are present，then they should removed by grinding，so as to
prevent damage to holes and bearings (metal spalling, adhesions, scratches, etc.).
c) If there is requirement in the Repair Manual，check ：
—If it is proper in fitting of hole with bearing or self-aligning bearing is.
—If compound used inside (lubricant, putty) is in compliance with specifications.
1.3 Prior to tightening-up，check the fitting condition of bearing or self-aligning bearing with
hole
— Overfit，pressing with hands can not make bearing or self-aligning bearing move in
hole.
— There should be no clearance between hole of shell and the outer face of bearing or
self-aligning bearing.
— Ensure axial locating between bearing or self-aligning bearing and shell side.
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— Slot position of removable bearing or self-aligning bearing should be correct.

Note: The only condition to limit the fit of bearing or self-aligning bearing in its shell is
the work freedom after tightening-up.
1.4 Inspection of tightening
1.4.1 General
— Check if tightening-up procedure is conducted as specified in the Repair Manual.
— The tightening-up should not cause deformation to bearing or self-aligning bearing
or hole of shell.
— The assembling and tightening-up procedure should not alter the performance of
bearing or self-aligning bearing, which should be achieved，particularly, rotating
and rotating moment should be within the limits specified in the production
document.
1.4.2 Tightening-up
— If all the crimp connections of shell are in good contact with outer race chamfer of
bearing or self-aligning bearing，then the tightening-up is satisfactory.
— The axial movement of bearing or self-aligning bearing in hole is not allowed.
a) Spherical tightening-up
Depth：0.9 mm diameter：2mm
b) Slot type tightening-up
Depth：0.5±0.1mm
1.4.3 Cracks
—Visually check using magnifier in maximum power of 8.
1.4.3.1 Six- slot tightening-up
— Slot is allowed to have one crack.
1.4.3.2 Spherical tightening-up
a) The tightening-up process with 6 indentations at most is allowed to have one
crack.
b) For the tightening-up process with 6 indentations, each six indentations are
allowed to have one crack, but, two cracked indentations shall be separated by
two crackless indentations.
1.4.4 Rotating and rotating moment
— Only under the case that there is such requirement provided in the Repair Manual，
these moments shall be measured.
1.4.5 Test requirement
— The axial loads that are listed in the table can not correspond to the axial static load
of bearing or self-aligning bearing.
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—The values selected are all appropriate to dimensions of outer race of bearing or
self-aligning bearing. ‘&16>’
6-slot type tightening-up Steel and aluminum alloy
Outer diameter of bearing and self-aligning Axial load (non-tightening-up) unit KN
bearing
mm Limit load
≤16 0.59
>16~20 0.98
>20~30 1.96
>30 2.94
Spherical tightening-up Magnesium alloy and aluminum alloy

Outer diameter of bearing and self-aligning
Axial load (non-tightening-up) unit KN
bearing
Limit load
mm Magnesium alloy Aluminum alloy

≤16 0.29 0.59
>16~20 0.49 0.98
>20~30 0.98 1.96
>30 1.47 2.94
1.4.6 Program and test results

Gradually add load to the outer race of bearing or self-aligning bearing and maintain it
for 30seconds.
The load should neither cause deformation, nor cause disengaging phenomenon.
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PENETRANT INSPECTION METHOD
1 General
1.1 Application scope
Penetrant flaw detection is a flaw detection method for surface open defects，which should
be used for metal and non-metal material. However, in comparison with other
non-destruction flaw detection method，the advantage is relatively simple both in
equipment and flaw detection material..
1.2 Principle
The penetrant liquid inspection is to utilize some characteristics of liquid to properly
penetrate to the material surface defects，and when the developer is sprayed on the surface
of part，the penetrant liquid remained in defects will absorbed out, thus a defect mark is
formed. .
1.3 Requirements for surface of parts
The parts must be thoroughly cleaned，and surface should be free from greasy dirt, rust,
paint coats, water logging and other pollutants.
Cleaned parts must be completely dried，so that no cleaning liquid or water inside defect
can adversely affect the penetration of penetrant liquid.
1.4 penetrant inspection personnel at all levels can only do the technical work related to their
own technical qualification.
The operating steps of penetrant flaw detection depends on penetrant liquid use and
development method，which is shown in the operation flow chart.
2.1 Fluorescent penetrant inspection
2.1.1 Immersing of parts
2.1.1.1 Immerse the well cleaned part into penetrant liquid of 540℃，so that surface of the
part can be completely covered, and the method such as brushing and spaying can
also be used.
2.1.1.2 Penetrating time 20-30min.
2.1.1.3 Surplus penetrant liquid on parts dripped into tank，and the dripping time is
5-10min.
2.1.2 Cleaning of parts
2.1.2.1 Self-emulsification penetrant liquid
a. Immerse the parts into an agitated water tank or use a water spray gun for
cleaning, the cleaning time is until the surface of parts clean, however no
overwash is allowed and generally, it is 1-2min.
b. In case the water spray gun is selected for cleaning，a regulator should
incorporated，so that a proper low pressure jet-flow can be produced, and the
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spray nozzle shall be at least 30cm from the part，the maximum pressure
0.1-0.3MPa.
c. Check the cleaning effect under ultraviolet lamp from surface of part when
strength is 800μm/cm.
2.1.2.2 Post-emulsification penetrant liquid
a. In emulsifying, use the same series of emulsifier for emulsification.
b. Emulsification time should be particularly strict, to ensure on condition that the
allowable background can be obtained, the contact time of emulsion with parts
shall be tried to be as short as possible.
c. In order to rapidly stop the emulsification of emulsion, immerse the parts into
agitated water.
d. Check the cleaning effect under the ultraviolet lamp from the surface of part
with strength of 800μm/cm
2.1.3 Drying of part
2.1.3.1 When thermal cycle air dry box is used，its temperature should be 80℃ and below，
dry time should be determined according to the geometric shape of a part.
Operation flow chart
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Dependant on shapes and sizes and quality of material, dry time should be as short
as possible, generally 3—8min.
2.1.3.2 When a part is locally dried, the forced circulating air (electric wind) may be used
fro drying, till the on surface of part disappears.
2.1.4 Dry powder developing
2.1.4.1 After dried, parts should be immediately applied with developing powder, enabling
part surface to be uniformly covered with a thin layer of developing powder.
2.1.4.2 Developing time should not be less than 15min.
2.1.5 Inspection of parts
2.1.5.1 Prior to inspection, use a pressure of not higher than 70 kPa (0.07MPa) remove
surplus toners, and the distance from nozzle to parts should be at least 30cm.
2.1.5.2 In dark room, use ultra violet lights to check parts.
2.1.5.3 After ultra violet light powered on and pre-heated for 10-15min, and only when its
intensity is not less 1000μm/cm at the place where ultra violet light is 380mm
away from part surface, can check be performed.
2.1.6 Final cleaning of parts
2.1.6.1 Developing powder should cleared away using a clean brush or wiper.
2.2 Dye penetration test method
2.2.1 Apply the liquid penetrant to upper surface of part, to let liquid penetrant be penetrated
into defects.
2.2.2 The penetrating time is generally 5min, but should not exceed 10min.
2.2.3 The cleaning solution is to wash extra liquid penetrant which is penetrated into outside
defects. When jetting the cleaning liquid, it should fast and the best way to jet the liquid
to part surface is inclined.
2.2.4 After clearing the liquid penetrant away the surface, wipe dry using a clean wiper, and
then use electric wind to slightly blow the surface, that is to use the developer agent to
develop defect.
2.2.5 Before using developer agent, the container must be fully shaken to make it uniformly
mixed.
2.2.6 The developer agent should be uniformly applied to surface of the part, and during
spraying; distance of 20-30cm between nozzle and part should be maintained. A
medium-moisture mist should be formed at the time of spraying.
2.2.7 After developer agent volatilized and dried on parts, red defect image will be developed
on the white film.
2.2.8 Part final cleaning
After completion of flaw detection, the penetrant and developer agent on surface of part
should be cleared up.
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MAGNETIC PARTICLE INSPECTION METHOD
1 General
1.1 Scope of application
The magnetic particle flaw detection is applicable to detect surface defects or near surface
defect of ferromagnetic material or made parts such as castings forgings weld and surface
defects or near surface of machined parts.
1.2 Principles
After magnetization based of ferromagnetic material, due to existence of defects, refraction
of magnetic line of flux is caused, resulting in leakage of part of magnetic flux out of the
part surface, and forming leakage field. If magnetic particle or magnetic suspension liquid
is applied to surface of parts, position and shape of defect will be developed.
1.3 Requirements for surfaces of parts
Oil stains, rusts, burrs, scales, metal chips and metal coats should be removed from the part
under detection.
1.4 Magnetic particle inspection personnel at different levels can only be engaged in technical
work corresponding to their technical qualifications.
2.1 Pre-treatment
Use solution, etc to get rid of many kinds of foreign matters harmful to defect
development from part surface, so as to obtain a good defect developing surface.
2.2 Magnetization
Select optimum magnetization method and magnetization current value as required so as
to get enough detection sensitivity. In addition, sensitivity test block can also be used to
select the magnetization current.
2.3 Apply magnetic particle or magnetic suspension liquid
There are two kinds of application methods- continuation method and residual field
method. The continuation method is to apply magnetic particle or magnetic suspension
liquid while applying magnetic field to a part, making magnetic field maintained until the
magnetic particle or magnetic suspension liquid is completely applied. The residual field
method is to apply magnetic particle or magnetic suspension liquid after magnetic field
applied to a part is completed.
2.4 Observation and judgment of magnetic tracks
There are two kinds of observation methods of magnetic particle tracks. When a
non-fluorescent magnetic suspension liquid is used, observation can be made in a place
where ray of light is available. If fluorescent magnetic particle or magnetic suspension
liquid is used, then ultra violet light has to be used to perform the observation in the dark
room.
For judgment of defect feature, review can be made with help of photo comparison or
other inspection means.
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2.5 Post- treatment

2.5.1 After flaw detection, the part should be demagnetization treated as required. The reason
for demagnetization is that if some parts which are with residual magnetism, then in
operation, they would attract iron chips, even a failure may occur. In demagnetization,
magnetic field strength will be reduced while a reverse magnetic field. There are two
kinds of demagnetization-direct current method and alternating-current method.
2.5.2 After demagnetization treatment of a part, the surface of the part should be cleaned.
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INSPECTION OF BEARING
1 General
This chapter specifies aspects as follows：
— Removal
— Cleaning
— Temporary protection treatment
— Identification before inspection
— Inspection
These bearings are from：
— Overhaul
— Repair
— Inspection has no influence on relevant TBO or developing part under test.
Description on packing of bearing is provided in 20-09-02-903 of this Manual.
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REMOVAL, CLEANING AND

PROVISIONAL PROTECTIVE TREATMENT OF BEARING
1 Removal, Cleaning and Provisional Protective Treatment of Bearing

1.1 Removal
— Carefully use a proper tools to remove a bearing form he assembly，prevent any
damages to bearing，and it is required to carry out the removal according to the
removal procedure specified in process card.
— After removal，the bearing should be placed in a separate container to prevent damages.
Each bearing shall be marked with part number using a metal label.
— Each container shall be exclusively used by a clearly specified assembly.
1.2 Cleaning
This cleaning method is applicable to the various types of abrasion resistant bearings：
— Standard or electro-plated (copper, cadmium, silver or tin plated) bearing.
—Bearing with metallic, celeron or polyamide retainer.
1.2.1 Equipment and material
— Ultrasonic cleaning instrument of using trichloro- trichloroethane (TTE) solution.
i.e.：Freon TF, FLugene113，Forane13.
— Perforated stainless steel basket.
— Nylon pad.
— Petroleum solvent
— Coarse gunny cloth, GRITE LOTH C400 or SCOTCH BRITE.
1.2.2 Cleaning method (see Fig.1)
a) For grease lubricated bearing：
— Put bearing (1) in basket (2), and protect it with nylon pad to prevent bearing
from contact with each other and the contact with basket wall.
— Start the ultrasonic cleaning device.
— Immerse the basket into the tank filled with solvent.
— shake the basket for 10min.
Note: The basket must be always be immersed into solution.
— Turn off the ultrasonic cleaning device.
— Take out the basket，and stay in solvent evaporating area for 30~40s，then unload
it completely.
b) For lubricating oil lubricated bearing：
— Use petroleum solvent and brush for cleaning .
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1.3 Temporary protective treatment

— Protective limit time: 48h.
— Immerse the bearing into the petroleum solvent，and dry it.
— If the limit time 48h is exceeded，the retreatment is required using petroleum solvent .
Fig. 1
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DETAIL RULES AND REGULATIONS ON BEARING INSPECTION
1 Inspection of Bearing
1.1 Identification prior to inspection
Repair of bearing shall be carried out according to the repair description in the relevant
aircraft manual. These descriptions are provided in the rules and regulations on reusing.
1.2 Inspection of bearings that can be completely or partially disassembled
1.2.1 Preliminary visual check
Visually check if bearings have following obvious defects.
— Cracked, broken and deformed balls, rollers, retainers and bearing races.
— Peeled balls, rollers and bearing races.
— overheating or burn marks.
Note: Mechanical pitting generally appeared in the gear box under lubrication with
“limit pressure” lubricating oil shall not form condition for discard.
— Slight corrosion on bearing races，balls or rolls can be removed using gunny cloth
dipped with petroleum solvent .
1.2.2 Magnetic particle flaw detection
It is applicable only to the bearings specified in the relevant aircraft manual.
— Carry out the cracks detection on a part.
— Demagnetize the part upon completion of magnetic particle flaw detection.
1.2.3 Check of residual magnetism
As per Aeronautical Specification 4580.
1.2.4 Detailed visual check
After checking as described in Articles 1.2.1, 1.2.2 and 1.2.3，unrejected bearings shall
be checked under magnification power of 2.5. (Higher magnification power may used
to determine the essence of defects that have already been found). All visible working
surfaces (that is, outer surface of balls, rollers, and track of bearing race) shall be
checked. It is possible to observe following defects：
— Dents and corrosions
Dent refers to a small pit. If size of any small pit exceeds 0.25mm (that is, if it can be
measured by using 1mm diameter receptor point)，that part shall be discarded. In case
of magnification power of 2.5, such small pits exceed 3 in any of scope of 5mm
diameter, or in 20mm on the bearing raceway such small pits exceed 3，then that part
shall be discarded.
— Indentation
Indentation is a slight surface concave or dent caused by pressure or collision of outer
surface with a hard matter. The indentation is generally similar to uniform surface area
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which normally appears on circular surface and can be detected only under reflected
light.
If it is found the indentation is more than 0.75mm (i.e. it can be detected by using 3 mm
diameter receptor point) that part shall be discarded.
If a roller indentation is more than 0.25mm (that is, if it can be measured by using 1mm
diameter receptor point)，that part shall be discarded..
— Peeling
Peeling is gradually surface raised，so it is also called surface fatigue.
If the peeling is found，discard that part, and particularly check if peeling has occurred
in cave or sunk area.
— Scratches
Scratches are linear surface scratches instead of scratches caused by boring, grinding,
polishing or finish lapping.
If a scratch is more than 0.25mm in width (that is, if it can be measured by using
1mm diameter receptor point)，that part shall be discarded.
— Circular scratches
The circular scratch refers to the presence of shallow dent on surface around balls or
rollers, and surface has no discontinuous traces.
If scratches in circumferential direction can be measured by using 1mm diameter
receptor point，then that part shall be discarded.
—Brinell effect indentation
Brinell effect indentation is a minor regular impression appeared on the bearing
surface，and it is possible to appear on two kinds of bearings - ball bearing and roller
bearing. All these are caused by improper assembling or due to violent vibration or
collision when bearing is not rotating. When roller bearing is checked with magnifier
under reflected light, this type of defects can be seen. The distance between center
points of the defect is in coincidence with that of balls.
If Brinell effect indentation can be measured by using 1mm diameter receptor point，
that part shall be discarded.
— False Brinell effect indentation
This is a kind of special type microvibration wearing corrosion that can only be found
on the bearing race contact surface, generally, which is on bearing of operating in a
small angle displacement. In general, it can be identified by a series of shallow
indentation by loading on bearing race of each roller contact surface on bearing
component.
This kind of defect is often accompanied by a red oxide.
If it can be detected by using 1mm diameter receptor point, that part shall be discarded.
— Stain
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Provided no pitting or overheating is present, then stain area is acceptable.

Stains can be locally wiped off by using gunny cloth dipped with petroleum solvent for
purpose of checking
— Worn dust proof cover and retainer
If retainer of ball or roller bearing has been elongated；if retainer is burnt and split；if
surplus fiber material is found or electroplated retainer is damaged，then the whole
bearing (if retainer group can not be removed) be discarded.
If surface peeling，or retainer deformation has caused two frictions and above，then that
part should be discarded.
Both internal and external contact areas of dust proof cover located by two races of
bearing may present uniformly worn sign on the sliding surface，and as long as the
radial clearance allowance on drawing can be ensured, then these parts are acceptable.
1.3 Inspection of non-detachable bearing
Check these bearings on the E-PEM-20-353 vertical lathe.
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REPAIR OF PARTS AND COMPONENTS

TABLE OF CONTENTS

20-03-01-101 General Description of Repair
20-03-01-102 Method of Rivet Removal
20-03-02-101 General Principle for Rivet Replacement
20-03-02-102 Marks of Rivets
20-03-02-401 Replacement of General Rivets
20-03-02-402 Replacement of “AVDEL” Rivets
20-03-02-403 Replacement of “JO” Screw Rivets
20-03-02-404 Principle for Replacement of “SLC” or “SLF” Rivet
20-03-02-405 Principle for Replacement of “HUC” Rivets
20-03-02-406 Principle for Replacement of “CHERRY-MAX” Cherry
Rivets
20-03-03-101 Replacement and Reinstallation of Anchor Nut
20-03-03-401 Reinstallation of Double Ear Anchor Nuts on Section
Bar
20-03-03-402 Replacement of Double Ear Anchor Nut with Single
Ear Anchor Nut
20-03-03-403 Replacement of Anchor Nuts on Flange
20-03-03-404 Replacement with Different Types of Anchor Nuts
20-03-03-405 Replacement of Double Ear Anchor Nut with Sliding
Anchor Nut
20-03-03-406 Installation of Band Type Floating Anchor Nut
20-03-04-401 Replacement of “LC” ASN-A0069 Series Nut
20-03-04-402 Replacement of “CAMLOC” Quick Release Fastener
NSA551-30
20-03-04-403 Replacement of “DZUS” Quick Release Fastener
NSA551.10-1 DZUS
20-03-04-404 Repair of Damaged Threads
20-03-04-405 Replacement of “VELCRO” Tape
20-03-05-401 Repair of Transparent Materials
20-03-05-402 Removal of Scratches Using Abrasion Polishing Method
20-03-05-403 Repair of Dimpling Cracks
20-03-05-404 Principle for Repair of Crack-arrest Holes
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REPAIR OF PARTS AND COMONENTS

TATBLE OF CONTENTS
20-03-05-405 Repair of Cracks on Sheet-metal Parts

20-03-05-406 Repair of Flange and Skin Cracks
20-03-05-407 Repair of Skin Cracks
20-03-05-408 Repair of Skin Cracks Between Stringers
20-03-05-409 Repair of Skin Cracks on Stringers Not Connected with
Skeleton
20-03-05-410 Repair of Skin on Skeleton Between Stringers
20-03-05-411 Repair of Skin on Skeleton and Stringers at Skin Joint
20-03-05-412 Repair of Cracks at Riveted Place on Skeleton Flange
20-03-05-413 Repair of Holes on Sheet-metal Parts
20-03-05-414 Repair of Holes on Fuselage Internal Structure
20-03-05-415 Repair of Holes on Fuselage External Structure
20-03-05-416 Repair of Cracks on Floor Between Stringers
20-03-05-417 Repair of Skin Holes on Stringers
20-03-05-418 Repair of Holes on skin between Stringers
20-03-05-419 Repair Method of Metal Sheet Cracks and Holes at
Sunken Area
20-03-05-420 Repair Method of Scratches, Cracks, Punctures of
Section Material
20-03-05-421 Repair Method of Cracked, Punctured Skin and
Damaged Section Material
20-03-05-422 Repair Method of Cracked, Punctured Skin and
Damaged Bulkhead
20-03-06-401 Repair of Honeycomb Structure
20-03-06-402 Repair of Laminated Structure
20-03-06-403 Repair of Welding Defect
20-03-07-101 Repair of Composite Material
20-03-07-401 Repair of Polycarbonate Cover
20-03-08-401 Repair of Non-slipping Cover
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GENERAL DESCRIPTION OF REPAIR
1 General
Repair is that a repaired part can recover its original condition in both appearance and
strength.
2 Description on Repair of General Structure
2.1 Determination of damage situation
Repair area is usually a clear damage area. Under normal case, two types of damages
should be taken into consideration：
— Damages which can be detected immediately，generally these damages are outside (due
to fire, lightning, accident, etc.) or damage that are easily be found in the course of
aircraft overhaul (shearing rivet, shearing or broken pipes etc.) .
— Damages which are difficult to be detected ， and need a system check and
disassembling (due to a forced landing, flights too much under turbulent state,
acceleration and shutdown, etc.).
In the first case，starting from identifying the location of damage，operators can determine
the area to be repaired by method such as checking the assemblies or parts nearby that are
suspiciously of damage，or comparing with the same damage found on the same type of
aircraft. Once the damage area is identified，operators should try to connect it with typical
damage. If necessary, confirm the correctness of damage classification，and make sure the
specified repair is one of the repair methods as described in this section or in compliance
with one of typical repair manuals specified in Repair Manual (M.R.R) which is related to
specific aircraft .
In the second case，it is required first to carry out system check，to identify the damaged
area. Once the damaged area is found，like the first case, first of all, the repair area should
be determined for the place to be repaired .
2.2 Fire damage
For the painted part involved, roughly put forward the scope of repair according to such
conditions as if painting coat is adhered to the part, and blistered and blackened.
2.3 Lightning damage
Generally, the damages are limited to：
— Local burn，in most cases , it can be repaired by skin drilling and riveting (damage is
generally evident and centralized).
—Bonding damaged on some parts, units or components should be bonded again (this
kind of damage is generally larger than the scope of the former，and it needs to
systematically check electric bonding condition of all neighboring metal parts).
2.4 Disassembling for evaluation and repair of the damage.
Disassembling (loosening and removal of rivet) is a careful work，on which the correct
repair is mainly based. During disassembling and repairing, take all necessary preventive
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measures to maintain the main dimensions.

This procedure must ensure：
1) During disassembling：
— It is required to compare the accurate dimensions with the original dimensions
appear in the specific inspection record of this aircraft and the structure repair
manual.
— Correct clamping parts to prevent any relative displacement and possible
deformation, as these phenomena is caused by the stress as result of some removed
structural parts.
2) During removal of rivets：
— It is required to check rivets，remove all the loose, cracked or deformed rivets
(deformation of rivet bars).
— Care should be taken to avoid inducing of cracking and elongation of hole, and any
defected rivets can be taken down by means of drilling rivet head.
— Generally, the elongated hole shall be re-machined to the next bigger diameter hole
(refer to interference diameter).
— Carefully identify all types of rivets，and also pay attention to their positions in
related parts (for this end，the riveting joint to be completed can be printed
punched paper tape using different diameter types of rivets at position located).
— When the repair can be carried on aircraft (when carrying out repair without fixture
is feasible, or when repairing a non-critical area)，the quantity all rivets previously
given should meat the requirements the reinstalled keeps the part in correct
position，and eliminate the variation caused by released stress.
2.5 Selection of repair material
The material to be used should be the material specified by the aircraft manufacturer,
which can be referred to the chapter-section of Material Identification in the Repair
Manual of each aircraft involved.
2.6 Selection of riveting mode
Repair should be often in such a way：The existing rivet pitches and edge distance should
be just properly reused (number of rows, quantity of rivets, pitches and edge distance) In
this case; only the diameter and type of rivet can be changed. If rivet is elongated or
deformed due to removal, then in most of cases, it is required to select next bigger
diameter rivet of the same type.
3 General Description on Hole Enlarging and Bolt Oversizing
The various accidents happened in flight and fatigue destruction added due to that cause
frequent increase of repair scope.
3.1 Use of oversized broaching
1) Connect a new part to structural member to be repaired：Systematically use the next
bigger oversizing.
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2) Two existing parts are connected to each other：Only use the original dimensions.
3) Connection of structural members that are removed for repair：Only under a case that
there is defect that needs to enlarge hole, use the oversizing. It is required to be as
much as possible to control this kind of use.
4) Drilling limits：It shall be limited to within the maximum allowable reaming diameter.
3.1.1 Quality of enlarged hole and allowed defects (see detail A in Fig.1)
— Under the most cases that tight fit tolerance bolts are used for connection，hole is
grade H7，bolt grade，and the actual operation, this is in compliance with tight fit
(assembling is performed using hammer)，and for this end, reaming tolerance of
grade H7 is needed for repair.
— For thick or solid holes on A-U4G20(7A),or A-U4G1(2024)，some marks and defect
A，such as sand blast hot mark and reamer marks are allowed provided they can
meet the following requirements.
a) The depth “h” of ideal enlarged hole on a part should be at least equal to “D”
(maximum approved broaching diameter).
b) Defects shown should be free from longitudinal scratches; otherwise, they should be
removed.
c) In any cases，maximum elongation or defect diameter “D1” both should not exceed
the 11％ of ideal enlarged hole diameter “D” .
Note: In case two parts of the same material with assembling thickness “e” and “e1”，
“h” should be only equal to “e”，as the sand blast stress of reliable broaching
section on the part (2) is at least equal to the sand blast stress of part (1).
3.2 Use oversized bolts
1) Two solutions can be use：
—Tightly fit the liner into oversized bore.
—Use oversized bolts in staggered way.
Note:
— Table 1 specifies the service limit values for the oversized bolts R1, R2, R3 and R4.
B B B B B B B B
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Fig. 1
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Table 1—Oversized Screws and Bolts
Nominal Oversizing
diameter R1 R2 R3 R4
mm mm mm mm mm
5 5.2 5.4 5.6 5.8
6 6.2 6.4 6.6 6.8
7 7.2 7.4 7.6 7.8
8 8.3 8.5 8.7 8.9
10 10.3 10.5 10.7 10.9
12 12.3 12.5 12.7 12.9
14 14.3 14.5 14.7 14.9
16 163. 16.5 16.7 16.9
18 18.3 18.5 18.7 18.9
20 20.4 20.7 21 21.3
22 22.4 22.7 23 23.3
24 24.4 24.7 25 25.3
26 26.4 26.7 27 27.3
28 28.4 28.7 29 29.3
30 30.4 30.7 31 31.3
Important note：Oversizing is applicable to polish rod portion
Note: In order to maintain the service life of each aircraft and its special connecting parts，
it is recommended that only when absolutely necessary, oversizing of screw and
bolt (R1, R2, R3 and R4) can be used. When the repair involves the connection of
interchangeable parts, based on requirement provided by the chapter “General” in the
“Repair Manual” of specific aircraft，the oversizing can not be used.
— It is possible for a higher value of oversized R2, R3 and R4，but careful study is required
and it should be approved by the engineering department of the manufacturer.
2) The first solution is to maintain nominal diameter of bolt should make it usable every
time, so that whenever the repair involves the connection of interchangeable part, this
type of repair can be used in every kind of parts.
3) The second solution is the essential structural part, which has already been discussed, can
only be used in a usable operation. Oversized bolt scheme is specially provided for bolt
connection of structural part with non-removable part which is connected with structural
part. When a liner is not to be fit under exceptional case, this solution can also be used
for the removable part.
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3.2.1 Oversized screw and bolt

For every nominal diameter，it is provided with oversized (R1,R2,R3 and R4). The
material of screw or bolt as well as machining allowance of screw or bolt shank shall
be the same as that of screw or bolt.
For definition of oversized screw and bolt, see detail B in Fig.1)
1 Oversized diameter (R1-R2-R3-R4)
2 Nominal diameter
3 Run-out of thread
a) Thread lead-out value
Thread Lead-Out Value and Corresponding Value of Pitch
Thread Pitch 0.7/0.8 1 1.25 1.5 2
a 2 2 2.8 2.9 3.3
It is valued for screw sand bolts without tool recess.

3.2.2 Identification of oversized screws and bolts (see detail C in Fig.1)
— “Repair” diameter value should be marked using 1/10mm increment value.
— Two digits marks，and the height of mark number (1) is 1mm，which is used on
countersunk screws (2)，hexagonal screws (3) and bolts (4) with diameter of
5~8mm.
— Three digits marks，and the height of mark number (5) is 2mm，which is used on
countersunk screws (6) and bolts (7) with diameter 10~30mm.
3.2.3 General tolerance of countersunk screw for assembling skin
1) Countersunk screws mounted on skin should not be protruded out of the skin：Screw
head can be sunk to a ranging from 0.00 to-0.20mm.
2) Screws mounted on aircraft internal structural parts.
0
Flush tolerance of screws mounted in aircraft: − 0.5 mm.
3) For screw position in countersunk hole, see detail A in Fig.2, and the maximum
clearance between screw countersunk and sheet countersunk hole is 0.07mm (1)，
which is not allowed to exceed the half of the screw head (2) circle.
4 General Description on trimming scratched structural parts
4.1 Standard for additional machining of critical parts
4.1.1 Assembly parts/units without limit of service life
Standard for additional machining is provided in each Structure Repair Manual (M, R,
R).
4.1.2 Assembly parts/units with limit of service life
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For the sake of safety，before carrying out any re-machining of these assembly
parts/uints，all customers are requested to inform The After-sale Support Engineering
Department of Harbin Aviation Industry Group Co. Ltd.
The Maintenance Manual lists out these assembly parts/units and specifies the
service life of each part.
4.2 Standard for additional machining of non-critical parts
Precautions：This document only includes assembly parts/units that are fixed on
structural member.
1) Method (see detail B in Fig.2)
— The additional machining should be limited to within given limits：the scratches
depth “X” should not exceed 3％ of metal thickness.
a) Thickness of areas marked with a, b, c and d should be taken into consideration，so
as to calculate the maximum depth “X”.
b) X value =maximum depth of scratch，which should be equal or less than 3％ of
thickness of area under consideration.
c) The additional machining should checked and approved according to the following
requirements：
— Scratches on one side：X= maximum allowable re-machining depth.
— Scratches on both sides：X1+X2=X
— Using a big radius fillet to merge remachined area together with original surface.
— When boring and determining its requirement for fit，refer to the method specified in
the relevant chapter-section of Fit and Tolerance in each Structure Repair Manual .
Precautions：
— Only one additional machining is allowed in the same profile
— The previous additional machining shall be taken into consideration.
— The additional machining shall be recorded in the inspection document.
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Fig. 2
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METHOD OF RIVET REMOVAL
1 Method of Rivet Removal

It is recommended to use a simple and practical method of rivet removal，so that rivet can
be correctly removed, and try as much as possible to prevent the existing rivet holes being
oversized.
1.1 The first method (see detail A in Fig.1)
1 —The first procedure：
Use drill bit (2) 2/10mm smaller than the rivet diameter to drill a hole on rivet head (1) ,
and use a mobile guide piece (3) fixed on drill bit head for centering.
2 —The second procedure:
Use the steel punching head (1) and rivet support block (2) to withdraw rivet.
1.2 The second method (see detail B in Fig.1)
1 — It fails to withdraw rivet according to the first method.
2 — The first procedure:
Use drill bit (1) 4/10mm smaller than the rivet diameter to drill a hole on rivet bar, the
depth of drilled hole shall be equal to depth of rivet.
3 — The second procedure:
Use steel punching head (2) and rivet support block (3) to withdraw rivet.
Note: These rivet removal methods are applicable to standard, single side and screw
rivets.
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Fig. 1
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GENERAL PRINCIPLE FOR RIVET REPLACEMENT
1 General
In order to perform repair which is not specified in the Structure Repair Manual, the rivet
type can be determined as described in the following：
Countersunk rivet with given original diameter or common head rivet should be replaced by
the same type but next big diameter i.e. called as “oversized” rivet.
However, if repairmen are able to effectively complete removal of actual rivet, that is, draw
out rivet under condition of not oversize the existing rivet hole, then repair of rivet can be
done using the rivet with the same diameter as that of original rivet.
This method can not be used in all kinds of repairs, but it has a special meaning in the
interchangeable assembly, where small diameter rivet can be used to reach the assembling
of additional part in the original structure.
As for replacement of 100° countersunk rivet on stamping sheet, repairmen should refer to
20-03-05-403 in Standard Practices Manual, including several types of typical repairs.
Flat head rivet can be replaced using single side rivet if required.
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MARKS OF RIVETS
1 Marks of Rivets
1.1 Aluminum alloy rivet
Identification Marks
Marking Material Remarks
and Color Marks
— Convex mark
A-G5
— Colorless mark
— Convex mark
A-U2G
— Colorless mark
— Convex mark
A-U4G1
— Colorless mark
For aluminum rivet ， the
— No marks red mark must be provided
A5 to prevent confusion with
— Red mark A-U4G100° countersunk
rivet.
— Convex mark
A-G5MC
— Green mark
— Concave mark
A-U2G
— Violet mark
— Convex mark
A-U4G
— Colorless mark
1.2 Cadmium plated steel rivet
and Color Marks
— Convex mark XC10
— Colorless mark XC12
— Concave mark XC10
— Colorless mark XC12
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1.3 Stainless steel rivet used under temperature of up to700℃

Marking Materials Remarks
and Color Marks
— Make two curved marks outside
rivet nominal diameter Z3CNl8-10
—Colorless mark
—Make three equidistant curved
marks outside rivet nominal
ZBbNCT25
diameter
—Colorless mark
— Concave mark
Z2CN218-10
— Limon color mark
Convex mark
Z6NCT25
— Colorless mark
1.4 Nickel alloy rivet used under temperature of up to 450℃

and Color Marks
— Use two radial relative convex

circle-dot to make marks N-U30
— Colorless mark
— Convex mark
N-U30
— Light blue mark
1.5 Nickel alloy rivet used under temperature of up to700℃

and Color marks
— Use three equidistant convex

circle-dots to mark outside rivet M.C15F8
nominal diameter
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1.6 Titanium rivet

Identification Mark
and Color Code
— Concave mark
N-C20T
— No color code
AS N-C15Fe rivet is used
— Convex mark only in France, so there is no
N-C15Fe international standardization
— No color code organization
(ISO) mark
— Convex mark
T40
— Colorless mark
1.7 China-made rivet materials and marks (extracted from GB1017)
Marking Identification Mark Material Remarks
No character Ly10
One concave point LY1
Two convex points LF10
Three convex points LF21
One convex line Ly4
One concave point One concave point
MLC15
ML10
No character 1C18Ni9Ti
H62
No symbol T3
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REPLACEMENT OF GENERAL RIVETS
1 General Rivets
1.1 Non-stamped sheet (see detail A in Fig.1)
Three types of rivets can be used
— Countersunk rivet (F)
— Half round head rivet (G)
— Oblate head rivet (C)
The length (L) and diameter (D) of rivet depends on thickness of combination plate piece
and type of rivet heading：
— Forming a brazier head (G′)
—Forming a oblate head (C′)
—Forming a countersunk (head F′)
1.2 Stamped sheet (see detail B in Fig.1)
Only countersunk rivet (F) is used for this kind of riveting：Head may be either oblate -head
(C), or half round-head (G)
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REPLACEMENT OF “AVDEL” RIVETS
1 “AVDEL” Rivet
AVDEL rivet is single side rivet，which can only be fed and installed from one side of
assembly part.
During installation process (a)，rivet core bar (1) comes into sleeve (2)，the sleeve will be
expended and completely fill the rivet hole，and finally with expansion included, surface
producing tail (b) .
Technical key elements of AVDE L rivet：
— Rivet head diameter (A)
— Rivet head thickness (B)
— Rivet length (C) of depending on riveted member thickness
— Rivet diameter (D)
— Riveted member thickness (S)
1.2 Installation of AVDEL rivet (see detail B in Fig.1)
The installation requires F type riveting gun with straight or 90° angle adapter. In some
cases, H type manual rivet pincers is also needed.
1.3 Technological procedure
— The first step (a)
Fit the sleeve (2) and core bar (1) on the position of riveted member.
— The second step (b)
Install the clamp (3)
— The third step (c)
Use the riveting gun to pull the core bar (1) into sleeve (2)，to the sleeve.
When the riveting completed，a tail will be formed on the sleeve，and core bar will be
automatically broken.
— The forth step (d)
Cut the broken head of the core bar，and smooth it, if required.
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Fig. 1
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REPLACEMENT OF “JO” SCREW RIVETS
1 Replacement of “Coupling Bolt” (JO-BOLT) Screw Rivets

1.1 General
“Coupling Bolt ” rivet is single side rivet，which can only be fed and installed from one
side of assembly part.
Countersunk rivet part No.：ASN-A0101
Hexagonal head rivet part No.：ASN-A0102
1.2 Definition of “Coupling Bolt”screw rivet (see detail A in Fig.1)
— The screw rivet consists of rivet shank (1)，lock ring (2)and core bar (3). The rivet head
is divided into two types- countersunk head and hexagonal head.
— Before installation (a)
— After installation (b)
— Thickness of riveted member (s)
1.3 Preparation of assembly parts
1) Clamp the parts to be assembled.
2) Perform locating holes for parts according to type of rivets to be installed.
3) Use locating bolts to correctly fix the assembly parts. There should be no more than 3
hollow holes between the locating bolts.
4) Drilling.
5) Separate assembly parts，and remove burs of hole from both sides of the part.
6) Never chamfer，and the chamfering will reduce contact area of lock ring flange.
7) Reassembling parts，and locating bolts to fix the assembly parts. There should be no
more than 2 hollow holes between locating bolts.
1.3.1 List of pre-drilled holes
Rivet part No. or Diameter of locating Diameter of pre-drilled Remarks
diameter code bolt hole
164 φ3.2 φ3.6
Refer to Section
190 φ4 φ4.0 1.4.2, Reamer
249 φ4.8 φ5.8 Graphical Chart
312 φ6 φ7.5
1.4 Ream to the final diameter

1.4.1 Recommendation
— The plates should be tightly fit to each other.
— Fixing of locating bolt should be in compliance with requirement of the note in Item
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7, Section 1.3.
— It is not allowed that existence of foreign matters or metal chips between assembly
plates.
— Holes must be reamed clean without burrs.
— The assembling tolerance must be in compliance with requirements.
1.4.2 List of reamers
(For the List of Pre-Drilled Holes, see Section 1.3.1)
Rivet part No. or diameter code Rough reamer Fine reamer
ASNAl01-164 Diameter 4 Diameter 4.20
ASNAl02-164
ASNAl01-190 Diameter 4.7 Diameter 4.83
ASNAl02-190
ASNAl02-249
ASNAl02-312
1.5 Spot-facing drill 100° countersunk socket，so as to install the countersunk coupling bolts
ASN-A0101
Use spot-facing drill Sd48.8.01 (diameter 10 and 14) and Sd48.08.02 (diameter 17) with
guide bar Sd48.0.09.
Use millesimal stop spot-facing drill arbor RB206.05 and RB306.22.14.
Before spot-facer drilling a aircraft part，at first make a trial drill on test specimen，and
adjust the spot-facing drill arbor，until the countersunk socket is in compliance with
tolerance.
1.6 Select the length of rivet according to requirements of thickness size of riveted member
(see detail B in Fig.1)
1) Rivet part No., rivet diameter and thickness of assembly parts must be taken into
consideration.
2) Code of rivet length (L) and clamping dimensions.
Clamping Diameter Diameter Diameter Diameter
Length
thickness Code Code Code Code
code
Min. Max. 164 190 249 312
02 2.4 4 12.7 13.1 15.1
03 4 5.6 14.2 14.7 16.7
04 5.6 7.1 15.7 16.3 183 20.6
05 7.1 8.7 17.5 17.8 19.9 22.2
06 8.7 10.3 19 19.4 21.5 23.8
07 10.3 11.9 20.6 21 23 25.3
08 11.9 13.5 22.1 22.6 24.6 26.9
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Fig. 1
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Clamping Diameter Diameter Diameter

Length Diameter Code
thickness Code Code Code
code
Min. Max. 164 190 249 312
09 13.5 15.1 23.9 24.2 26.5 28.5
10 15.1 16.7 25.4 25.8 27.8 30.1
11 16.了 18.3 26.9 27.4 29.6 31.7
12 18.3 19.8 28.4 29 31 33.3
13 19.8 21.3 30.5 32.6 34.8
14 21.3 23 32.1 34.2 36.4
15 23 24.6 33.7 35.7 38
16 24.6 26.2 35.6 37.3 39.6
1.7 Check the sandwich thickness

Use a standard gauge 81.5.08 or when the thickness exceeds 30mm, use a depth gauge or
hook headed micrometer.
1.8 Installation of “coupling bolts” rivet
— For riveting tools, see Article 1.15.
— Embed a rivet completely into hole.
— Use a proper wrench or riveting gun.
— Insert a rivet bar into bush to start the riveting tool.
— Align the sleeve with the fixed rivet head (countersunk notch，convex hexagonal head).
— Start the tool，until the rivet core bar is pulled apart .
Note:1) When collar or back side is against plate AG3/AG5-MC with thickness of 1mm
or thinner，it is prohibited to use this kind of rivet .
2) Rivet is greased, but no degreasing is required or no extra machining is to be
conducted, which must be installed with existing lubricating oil.
1.8.1 Riveting procedure of rivet (see detail C in Fig.1)
— The first step (a)
Fit the bush (1)，collar (2) and core bar (3) on the riveting gun，and install rivet
assembly into hole of part to be assembled.
— The second step (b)
The core bar will be drawn out by riveting gun，and the collar edge be flanged by
force .
— The third step (c)
The core bar shall be cut at the outside the plate which shall be flush with rivet head，
and if required，it can be smoothed.
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1.9 Check the broken situation of rivet core bar (see detail A, B in Fig.2)
Check as described in table below.
Fig. 2
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Rivet Part No. and Code IL Alloy-steel Rivet Code and Code IL Alloy-steel
Diameter Code Min. H Max. H Diameter Code Min. H Maximum H
ASNAl01-164 -1.70 +0.50 ASNA102-164 0 2.25
ASNAl0-190 -2.10 +0.40 ASNAl02-190 0.25 2.65
ASNAl01-249 -2 +0.25 ASNA102-249 1.20 3.45
ASNAl01.312 -2.10 +0.30 ASNA102-312 0.85 3.70
1.10 Check fixing condition of rivet head (see detail C in Fig.2)

1) Hexagonal head
The maximum allowable clearance between the rivet head and plate is 0.10mm(1)，
however：
— The rivet with this kind of defect in one row of rivet should not exceed total amount
of rivets by 10％.
— Two such continuous rivets with this kind of defect are not allowed.
2) Countersunk head
The maximum allowable clearance between the rivet head and plate is 0.07mm (2)，
however：
— The clearance should not exceed half of periphery.
— In one row of rivets, it is not allowed to exceed total amount of rivets by 20％.
— Two such continuous coupling bolt rivets are not allowed.
1.11 Riveting on the non-parallel surface (see detail D in Fig.2)：Maximum 7°
It is valid for the tail of countersunk rivet and hexagonal head rivet.
1.12 Refinement of broken rivet core bar
If rivet core bar is protruded，in order to prevent damage to aircraft equipment，it must be
smoothed with a finishing tool, the filed area shall be protected as required in drawing.
1.13 rivet core bar protective treatment
Refer to description of the relevant repair manual.
1.14 Flush tolerance of countersunk rivet ASNA101
Refer to specifications involved to each aircraft, and if unavailable, as per French standard
NFL-21-208.
1.15 “Coupling Bolt” riveting tool
— Table 1-COMET tool.
— Table 2-MONOGRAM and LOCK-FAST tool.
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Table 1
Pneumatic Rivet Gun
Rivet Wrench
Part No.728
Rivet head
Standard Ultra Thin
Type Driver Socket
Box Box
ASNAl01-164 100° countersunk 7280-2105 7280-3005 7180-0005 7300-0005
ASNAl02-164 Hexagonal 7280-2105 7280-4005 7181-0005 7301-0005
ASNAl02-190 Hexagonal 7280-2106 7280-4006 7181-4006 7301-0006
ASNAl02-249 Hexagonal 7280-2108 7280-4008 7181-0008 7301-0008
ASNA102-312 Hexagonal 7280-2110 7280-4010 729l-0010 7311-0010
Table 2
Diameter of riveting gun Right angle Rivet Gun
MONOGRA MLOCKFAST MONOGRA
Rivet MLOCKFAST
MP 550 450 Type MR 550
Rivet head 7440 Type
Type MTD Type
Trailing Trailing Trailing Trailing Edge
Type
Edge Part Edge Part Edge Part Part
100°
ASNAl01-164 MPF5A TDl65 MRP-5A PW465
countersunk
100°
ASNA101-190 MPF6A TD200 MRF-6A PW400
countersunk
100°
ASNAl01-249 MPF8A TD260 MRF-8A PW460
countersunk
100°
ASNAl01-312 MPn0A TD312
countersunk
ASNAl01-164 Hexagonal MPP5A TDl65P MRP.5A PW465P
AfSNAl01-190 Hexagonal MPP6A TD200P MRP-6A PW400P
ASNA101-249 Hexagonal MPP8A TD260P MRP-8A PW460P
ASNA101-312 Hexagonal MPn0A TD312P
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1.16 Reamer used for installation of “Coupling Bolt” rivets

Diameter Tolerance Limit Reaming
Pre-drilled hole of Reaming Reamer Part No. Diameter
(mm) (mm) (mm)
φ3.6 4.19 to 4.23 931 9240 421 or 2A126/Z9-67 4.21
φ4 4.82 to 4.87 931 2940 482 931 2940 485 4.82

Or 2A126/Z9-69 4.85
φ5.8 6.32 to 6.37 931 2940 633 931 2940 634 6.33
931 2940 635 or 2A126/Z9-65 6.34
6.35
φ7.5 7.91 to 7.96 931 2940 791 931 2940 792 7.91
931 2940 793 931 2940 794 7.92
931 2940 796 or 2A126/Z9-125 7.93
7.94
7.96
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PRINCIPLE FOR REPLACEMENT OF “SLC” OR “SLF” RIVET
1 SLC or SLF Rivet

SLC or SLF rivet is a connecting part which combines the maximum advantages of two
kinds of most conventional connecting methods- rivet and screw.
1.1 Definition of SLC and SLF rivet (see detail C and detail B in Fig.1)
SL rivet consists of core welding and collar
— Rivet diameter (1)
— Nominal length (2)
— Total length (3)
— Sheared groove
— Assembly thickness (equal to the nominal length (2) plus or minus 0.75mm)
— Collar (5)
— Post-fitting protective treatment (6)
1.2 Installation of SLC or SL rivet (see detail C in Fig.1)
The installation requires to use a pneumatic riveting gun or hydraulic riveting gun，and the
riveting gun should be provided with an adapter which can be varied with rivet diameter
and installation position.
1.2.1 The first step (a) —Locating of rivets
After installation of core bar (1) and collar (2)，riveting gun (4) should be slided over
core bar (1)，with its snap die (3) held out against collar (2). Then, automatic clamping
device (5) will grip the recessed core bar (1).
1.2.2 The second step (b) —installation of rivet
As the result of action of riveting gun，so clamping chuck (5) is separated from the snap
die (3)，and insert the rivet core bar into hole .
1.2.3 The third step (c) — clamp collar
With increase of pulling force of rivet core bar，riveted member is closely joined by
extrusion，collar (2) shall be compression deformed by the snap die (3)，and inlaid in
circular groove.
1.2.4 The forth step (d) —Pull apart core bar
After completion of press fitting，rivet core bar will be pulled apart at circular groove.
1.3 Check installation of rivet
Refer to the task card 20-02.04.601 of this manual.
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Fig. 1
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PRINCIPLE FOR REPLACEMENT OF “HUC” RIVETS
1 “HUCK” Rivets
1.1 Countersunk or button-head “HUCK” rivet is single side riveting type rivet，which is set
and fixed form one side riveted assembly parts.
1.2 Definition of “HUCK” rivet (see detail A in Fig.1)
Rivet consists of core welding (3) and collar (4)
— Rivet diameter (1)
— Use countersunk “HUCK” rivet (1)
— Button-head “HUCK” rivet (2)
— Riveted member thickness (5)
1.3 Installation of “HUCK” rivet (see detail B in Fig.1)
The installation needs a specially made rivet clipper and pneumatic riveting gun, pincer
clamp or riveting gun should be equipped with replaceable cupping tool which is selected
according to the rivet dimensions and assembling space position.
1.3.1 The first step (a) - to make rivet expended
Fit tubular-shank rivet (1) together with core bar (2) mounted in push rod (3) onto the
rivet pincer clamp，and insert the whole rivet assembly into the rivet hole.
Operate the rivet pincer clamp to make core bar (2) enter into tubular-shank rivet (1)，
and then the rivet will be expended till the hole is fully filled.
1.3.2 The second step (b) - to form a blind side rivet head
After expansion of tubular-shank rivet (1)，as the pulling force is continuing to act on
the core bar (2)，so the tubular-shank rivet will be compressed between the head at the
end of core bar side and the head on the side of rivet pincers，and a blind rivet head
formed. The collar head at the end of core bar plays role of head to flatten the end of
tubular-shank rivet，and form a blind side rivet head.
1.3.3 The third step (c) - to mechanically lock the assembly part
After formation of rivet head, the riveting tool will automatically apply pressure to the
lock ring (4) in the conic space located in between the rivet head convex end and lock
annular groove of core bar (2)，thus interlocking two parts in the permanent rigid
assembly part.
1.3.4 The forth step (d) - to pull apart the core bar
Then，core bar (2) is continuing to be pulled, and it is pulled apart on the groove at the
flush point of tubular-shank rivet head (1). Hence, the core bar has no more ledges, and
an individual procedure to cut the core bar is not required. After breaking of core bar,
the fractured surface shall be coated with paint.
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Fig. 1
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PRINCIPLE FOR REPLACEMENT OF

“CHERRY-MAX” CHERRY RIVETS
1 “CHERRY-MAX” Rivet
1.1 General
— Use a kind of most reliable tool equipment and it is easy in installation.
— Advantages of this kind of rivets：
a) It is always able to be disconnected in flush with surface.
b) Simple in operation.
c) Well fixed core bar.
d) Reliable clamping.
e) High shearing strength.
f) Nominal diameter or super large diameter can be selected.
2 Description (see Fig.1)
Fig. 1
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— Rivet includes 4 parts as follows：

a) With shear groove (5), thrust ring (2) and slot to ensure gripping of lock ring (3), and
there is core bar (1) annular groove at the end.
b) Mechanically lock the core bar used lock ring (3).
c) Rivet bush (4) with internal groove filled and leveled up by deformation of the lock ring.
d) Anvil block acted as shear core bar (1) and crimp contact the washer (6) used for lock
ring (3).
3 Selection of Rivet Types to Te Used
— CHERRYMAX rivet diameter can use either nominal or oversized one.
Note: Oversized diameter shall be equal to the nominal diameter plus 0.40mm.
— Three types of rivet heads can be used：
a) Flat head
b) 100° countersunk head (MS20.470).
c) 100° countersunk head (MS20 426).
— Based on the requirements for positions where rivet holes are located，rivets shall be
made of different materials：
a) Aluminum 5056(AG5) - temperature to 120℃.
b) Nickel-copper alloy - temperature to 492℃
c) Inconel - temperature to 760℃.
4 Riveting Method (see Fig.2)
The first step (see detail A in Fig.2)
— Put the annular groove end of core bar (1) into pincer clamp of tool contactor (10)，until
the anvil block washer(6) touches end face of contactor (10).
The second step (see detail B in Fig.2)
— When the tool acts，the rivet core bar (1) is pulled into rivet bush (4). Core bar (1) stop
ring (2) will make the inner end of rivet bar form a big rounded end, which is pressed
against the plate (u) and connect plates together. The bush (4) will be expended between
stop ring (2) and anvil block washer (6) as it is compressed.
The third step (see detail C in Fig.2)
— When the tool acts，it will continue pull the rivet core bar (1)，and shear the lock ring(3)，
to make it slide to the area of core bar (1) conical head，allowing the rivet to be suitable
for thickness of riveted plate. The sliding distance will vary with the thickness of
assembly part，and rivet is designed according to the thickness of assembly part.
— Pull the core bar to allow the lock ring (3) to touch the anvil block washer (6).
The forth step (see detail D in Fig.2)
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Pressure of lock ring (3) acting on anvil block washer (6) will make it itself be deformed，
and be compressed to the lock groove of rivet bush (4)，to make core bar (1) locked，and
continue to pull the core bar (1)，flush shear the core bar from rivet head.
Fig.2
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5 Table for Nominal Diameter Flat-Head Rivet
Diameter A B D
Z Bore
Reference +0254 +0.254 +0.076 S
Minimum Diameter
No. -0254 -0.000 -0.025
-4 φ6.35 1.37 φ3.20 φ1.85 22.10 3.28-3.35
-5 φ7.93 1.70 φ3.90 φ2.31 23.88 4.06-4.16
-6 φ9.53 2.03 φ4.80 φ2.79 23.88 4.88-4.97
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Clamping Diameter Mark No.：4 Diameter Mark No.：5 Diameter Mark No.：6
Thickness Diameter 3.20 Diameter 4.00 Diameter 4.80
K K K
Min. Max. NO L Max. NO L Min. NO L Min.
0 0 0
-0.76 -0.76 -0.76
1.58 4-1 4.08 9.60 5-1 4.75 16.41 6-1 5.56 11.94
1.59 3.19 4-2 5.60 10.43 5-2 5.84 11.94 6-2 6.66 12.95
3.28 4.79 4-3 7.29 12.95 5-3 7.42 13.46 6-3 8.26 14.48
4.80 6.35 4-4 8.86 14.48 5-4 9.02 14.99 6-4 9.83 16.26
6.36 7.92 4-5 10.06 16 5-5 10.62 16.5l 6-5 11.43 17.78
7.93 9.52 4-6 12.04 17.78 5-6 12.19 18.29 6-6 13.01 19.30
9.53 11.09 4-7 13.64 19.30 5-7 13.79 19.56 6-7 14.61 20.83
11.10 12.70 4-8 15.21 20.83 5-8 15.37 21.34 6-8 16.18 22.35
12.7l 14.28 4-9 16.81 22.35 5-9 16.97 22.86 6-9 17.78 24.13
14.29 15.88 5-10 18.54 24.38 6-10 19.35 25.65
15.89 17.45 6-11 20.96 27.18
17.46 19.05 6-12 22.53 28.70
Drill bit φ3.3 φ4.1 φ4.9
diameter
Diameter Tightening Part Rivet Bar Core Bar

Mark No. Min. Thickness No.
-4 0.635 CR3213 Aluminum Steel
-5 0.787 CR 223 Aluminum Stainless steel
-9 0.940 15-7PH
CR3523 Nickel-copper alloy Stainless steel
15-7PH
CR3523P Cadmium plated Stainless steel
nickel-copper alloy 15-7PH
6 Tolerance Diameter 100° Countersunk Rivet and Countersunk Hole Size C
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Diameter A D Bore
Mark +0.102 B +0.076 S 2 Diameter C
No. -0.102 -0.025 φ
-4 φ5.71 1.04 φ3.20 φ1.85 22.10 3.28-3.35 5.64-5.79
-5 φ7.26 1.37 φ3.90 φ2.31 23.88 4.06-4.16 7.19-7.35
-6 φ8.97 1.73 φ4.80 φ2.79 23.88 4.88-4.97 8.89-9.04
Thickness Diameter 1/8 Diameter 5/32 Diameter 3/8
K NO K K
Min. Max. NO L Max. L Min. NO L Min.
0 0 0
-0.76 -0.76 -0.76
3.19 4-2 5.69 11.43 5-2 5.84 11.94 6-2 6.66 12.95
3.20 4.79 4-3 7.29 12.95 5-3 7.44 13.40 6-3 8.26 14.48
4.80 6.35 4-4 8.86 14.48 5-4 9.02 14.97 6-4 9.83 16.26
6.36 7.92 4-5 10.46 16 5-5 10.62 16.51 6-5 11.43 17.78
7.93 9.52 4-6 12.04 17.78 5-6 12.19 18.29 6-6 13.01 19.30
9.52 11.09 4-7 13.64 19.30 5-7 13.79 19.56 6-7 14.61 20.83
11.10 12.70 4-8 15.21 20.83 5-8 1537 21.34 6-8 16.18 22.35
12.71 14.28 4-9 16.81 22.35 5-9 16.97 22.86 6-9 17.78 24.13
14.29 15.83 5-10 18.54 24.38 6-10 19.35 25.65
15.89 17.45 5-11 20.14 25.91 6-11 20.96 27.18
17.45 19.05 6-12 22.53 28.70
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Minimum
Diameter
Clamping Part No. Rivet Bar Core Bar
Mark No.
Thickness
-4 1.60 CR3212 Aluminum Steel
-5 1.56 CR3222 Aluminum Stainless steel 15-7PH
-6 2.03 CR3522 Nickel-copper alloy Stainless steel 15-7PH
CR3523P Cadmium plated Stainless steel 15-7PH
nickel-copper alloy
7 Table for Oversized Diameter Flat-Head Rivet

Diameter A B D
Z Bore
Reference +0254 +0.254 +0.076 S
Min. Diameter
No. -0.254 0 -0.025
φ.35 1.37 φ3.56 φ2.06 22.10 3.63-3.71
φ.93 1.70 φ4.39 φ.54 23.88 4.47-4.45
φ.53 2.03 φ5.13 φ.97 23.88 5.21-5.31
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Clamping Diameter Mark No. : 4 Diameter Mark No. ::5 Diameter Mark No. ::6
Thickness Diameter 1/8″ Diameter 5/32″ Diameter 3/10″
K K K
Min. Max. NO L Max. NO L Max. NO L Max.
0 0 0
-0.76 -0.76 -0.76
1.59 4-1 4.44 9.39 5-1 5.16 10.92 6-1 6.15 11.43
1.60 3.19 4-2 6.04 11.60 5-2 6.248 11.94 6-2 6.73 12.70
3.20 4.79 4-3 7.64 13.21 5-3 7.848 13.46 6-3 8.331 13.97
4.80 6.35 4-4 9.22 14.73 5-4 9.423 15.24 6-4 9.906 15.75
6.36 7.92 4-5 10.82 16.51 5-5 11.023 16.76 6-5 11.506 17.27
7.93 9.51 4-6 12.39 18.03 5-6 12.598 18.29 6-6 13.08l 18.80
9.52 11.09 4-7 13.99 19.81 5-7 14.198 20.06 6-7 14.691 20.83
11.10 12.70 4-8 15.57 21.34 5-8 15.773 21.59 6-8 16.256 22.60
12.71 14.28 4-9 17.17 22.86 5-9 17.373 23.11 6-9 17.856 24.13
14.29 15.88 5-10 19.948 24.89 6-10 19.43l 25.65
15.89 17.45 6-11 21.031 27.18
17.46 19.05 6-12 22.06l 28.96
Minimum
Diameter Part
Clamping Rivet Bar Core Bar
Mark No. No.
Thickness
-4 0.63 CR3243 Aluminum alloy Steel
-5 0.79 CR3253 Aluminum alloy Stainless steel 15-7PH
-6 0.94 CR3553 Nickel-copper alloy Stainless steel 15.7PH
8 Oversize Diameter 100° Countersunk Rivet and Countersunk Hole Dimension C
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Diameter A D Bore
Mark +0.102 B +0.076 S Z Diameter C
No. -0.102 -0.025 φ
-4 φ5.72 0.89 φ3.56 2.06 22.10 3.6-3.71 5.64-5.79

-5 φ7.26 1.19 φ4.36 2.54 23.88 4.47-4.57 7.17-7.35
-6 φ8.97 1.60 φ5.13 2.97 23.88 5.21-5.31 8.89-9.04
Thickness Diameter 1/8″ Diameter 5/32″ Diameter 3/16″
K K K
Min. Max. NO L Max. NO L Min. NO L Min.
0 0 0
-0.76 -0.76 -0.76
3.59 4-2 6.04 11.43 5-2 6.76 11.94 6-2 6.73 12.19
3.20 4.79 4-3 7.64 13.21 5-3 7.848 13.46 6-3 8.331 13.46
4.80 6.35 4-4 9.22 14.73 5-4 9.423 15.24 6-4 9.906 15.75
6.36 7.92 4-5 10.82 16.51 5-5 11.023 16.76 6-5 11.506 17.27
7.93 9.51 4-6 12.39 18.03 5-6 12.598 18.29 6-6 13.081 18.80
9.52 11.09 4-7 13.90 19.81 5-7 14.198 20.07 6-7 14.691 20.83
11.10 12.70 4-8 15.57 21.34 5-8 15.773 21.59 6-8 16.256 22.60
12.7l 14.28 4-9 17.17 22.86 5-9 17.37 23.11 6-9 17.856 24.13
14.29 115.88 5-10 18.95 24.89 6-10 19.431 25.65
15.89 17.45 6-11 21.031 27.18
17.46 19.05 6-12 22.606 28.96
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Minimum
Diameter
Clamping Part No. Rivet Bar Core Bar
Mark No.
Thickness
CR3242 Aluminum Steel
4 1.14 CR3252 Aluminum Stainless steel 15-7PH
5 1.60 CR3552 Nickel-copper alloy Stainless steel 15-7PH
CR3553P Cadmium plated Stainless steel 15-7PH
6 1.85 Nickel-copper alloy
9 Riveting Tool
9.1 Advantages of the tool
— Easy in operation.
— Riveting contactor can be used for two types of rivets (flat-head and countersunk) with
diameter of 1/8-5/32 and 3/16inches.
— CHERRY MAX rivet can use the CHERRY MAX or CHERRY LOCK tool，and the
installation may select contactor according to two types of rivet heads and three
diameters .
— According to different riveting areas，there are three riveting contactors：
a) Straight contactor：P/NH701A-456.
b) Right angle contactor：P/NH753-456.
c) Eccentric contactor：P/NH736-456 and H751-456.
9.2 Tools
9.2.1 Manual pincer clamp
— Type G.36：with riveting contactor H9015-4C，only applicable to rivets with
diameter of 1/8 inches.
— Type G.55：with riveting contactor H9040-4C，used for rivets with diameter of 1/8
and 5/32inches；with riveting contactor H9040-5C，used for rivets of diameter of
3/16 inches..
9.2.2 Hydraulic tool
Type 40E，with riveting contactor H9040-4C，used for rivets with diameter of 1/8 and
5/32 inches；with contact H9090-5C，used for rivets with diameter of 3/16inches.
9.2.3 Combination hydraulic tool
— Type G.684, with riveting contactor H680B-200，used for rivets with diameter of 1/8,
5/32 and 3/16inches.
— Type G.700, with riveting contactor H701A-456，used for rivets with diameter of
1/8, 5/32 and 3/16inches.
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— Type G.784, with riveting contactor H680B-200 or H701A-456，used for rivets with
diameter of 1/8, 5/32 and 3/16 inches.
— Type G.685S, with riveted contact H680B-200, which is used for rivet with diameter
of 1/8, 5/32 and 3/16 inches.
9.2.4 Maintenance and repair of tools
See the Manufacture Manual TECNIMATIC (France) and DIVISIONS OF
TOWNSEND (USA).
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REPLACEMENT AND REINSTALLATION OF ANCHOR NUT
1 General
In some repair process, operator is generally required to replace and reinstall various anchor
nuts installed at different positions (to install removable metal plates, sectionalized member,
access cover and supports, etc.).
As it is unlikely to cover all the possible repair forms, so the following examples will only
describe the general repair principle.
Note: In any cases, the number of nuts that must be reinstalled is not allowed to exceed
20% of total amount of nuts in the area to be repaired (as the original screw hole is
elongated).
For certain reason, number of nuts that must be replaced has exceeded the given percentage,
and then the backing strip must be used.
If backing strip is used, then the quantity of anchor nuts to be newly installed will not be
limited.
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REINSTALLATION OF DOUBLE EAR ANCHOR NUT ON SECTION BAR
1 Reinstallation of Double Ear Anchor Nut on Section Bar (see Fig.1)

Replaced anchor nut (1) should be riveted on 1.2 ram thick LY12BCZ or France material
A-U4G1-T1-A5 backing strip by using use standard 100° countersunk rivet (3).
The backing strip should be riveted on section bar by using 100° countersunk rivet (4).
The existing screw hole on section bar should be expanded and drilled to an ellipse hole.
The existing anchor nut rivet hole (6) on section bar shall be filled and leveled up with
epoxy resin or XM-22Bor France material PR1221B sealant.
Fig. 1
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REPLACEMENT OF DOUBLE EAR

ANCHOR NUT WITH SINGLE EAR ANCHOR NUT
1 Replacement of Double Ear Anchor Nut With Single Ear Anchor Nut in Existing Rivet
Hole (see Fig.1).
Newly replaced single ear anchor nut (1) shall be riveted on 1.2mm thick LY12BCZ or
France material A-U4G1-T1-A5 backing strip (2) by using a standard 100° countersunk
rivet.
Backing strip will be riveted using existing rivet hole, and rivets to be used should be
diameter-oversized AU4G100°countersunk head rivet(4).
The existing screw hole (5) should be expanded and drilled to an ellipse hole.
All existing rivet holes (6), which have not been used to rivet the backing strip, shall be
filled and leveled up with epoxy resin or XM-22B or France material PR1221B sealant.
Fig. 1
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REPLACEMENT OF ANCHOR NUT ON FLANGE
1 Replacement of Anchor Nut on Wide Edge (see Fig.1)

Single or double ear anchor nut (1) will be fixed on flange using standard 100°countersunk
rivet (2), staggered from the previous installation position by 90°.
Rivet holes of original anchor nuts on edge shall be firmly riveted in C type head (3) using
100° countersunk aluminum rivets.
Fig. 1
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REPLACEMENT WITH DIFFERENT TYPES OF ANCHOR NUTS
1 Replacement of the Same Type of Anchor Nuts with Different Types Anchor Nuts (see
detail A.B in Fig.1)
Sometimes, it is required to use different types of anchor nut to replace the same types of
anchor nuts (Fig. A)，to obtain a modified assembly part (detail B). Position No.1 shows the
existing rivet，and position No.2 shows the rivet to be used for repair.
1.1 Temporary locating of anchor nut (see detail C in Fig.1)
In the drilling and riveting procedure of fixed part，anchor nut (2) shall use one set of
fastener(screw, nut and washer) for locating .
1.2 Use different types of anchor nut to replace the existing anchor nut(see detail a-a，b-b, c-c,
d-d sections refer to detail B in Fig.1).
1.2.1 Serviceable existing rivet hole (detail B inner section a-a in Fig.1).
— Anchor nut (1) uses the existing rivet hole to be enlarged，and use oversized
A-U4G100° countersunk rivet (2) for riveting .
— Unused rivet hole (3) shall be riveted fast in C type forming head using aluminum
alloy 100° countersunk rivet.
Screw hole (4) on the plate will be expending-drilled into elliptical hole.
1.2.2 Unusable Existing rivet hole (see detail B, section b-b in Fig.1)
Unused existing rivet hole (1) shall be riveted fast in “F” type forming head using
aluminum alloy 100° countersunk rivet.
1.2.3 Useable floating anchor nut (see section c-c in detail B of Fig.1)
Floating anchor nut (1) shall be riveted on 1.2mm thick LY12BCZ or French material
A-U4G1-T-A5 packing strip (2) using a standard 100° countersunk rivet (3).
Packing strip shall be riveted on the fixed part using a standard 100° countersunk rivet
(4).
Unused rivet hole (1) shall be riveted fast in “F” type forming head using aluminum
alloy 100° countersunk rivet.
1.2.4 Useable cat ear like anchor nut (see section d-d in detail B of Fig.1).
Unused existing rivet hole (1) shall be riveted fast in “F” type forming head using
aluminum alloy 100° countersunk rivet.
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Fig. 1
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Fig. 2
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REPLACEMENT OF DOUBLE EAR

ANCHOR NUT WITH SLIDING ANCHOR NUT
1 Replacement of Double Ear Anchor Nut with Sliding Anchor Nut (see Fig.1).
Newly replaced sliding ear anchor nut (1) shall be riveted on 1.2mm thick LY12BCZ or
France material A-U4G1-T1-A5 backing strip (2) by using a standard 100° countersunk
rivet.
Backing strips will use existing rivet hole, and they will be riveted and fixed using
oversized AU4G100°countersunk head rivet (4).
Original screw hole positions (5) will be used to rivet sliding anchor nut supports (6).
Fig. 1
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INSTALLATION OF BAND TYPE FLOATING ANCHOR NUT
1 Installation of Band Type Floating Anchor Nut on Laminated Skin

Fig.1 describes connecting method of ribbon type self-locking floating double wing
anchor nut L22.551, which is used screw of diameters 4 and 5.
Place the ribbon type floating self-locking anchor nut (1) in between laminated skin (2)
and cold curing pre-impregnated fiber washer (3).
1.2 Procedure (see detail B in Fig.1)
— On glass cloth laminated skin，drill one hole in consistence with diameter of screw to
be used..
— Provide assemblies as follows：
• Skin, plate, nut (1) and impregnated GENIN390 fiber washer (2) with polyester A288.
• Fix the above assembly on a fixture，and this fixture is provided with thrust plate (3) and
5 mm thick base plate (4) coated with isolating agent，and carry out assembling using a
pin type quick release locating clip (5).
— Before installation of ribbon type floating anchor nut，use an emery paper to sand the
glass cloth laminated skin surface, and degrease using trichloroethylene.
— Anchor nut should be degreased using trichloroethylene.
— GENIN fiber glass shall be gummed according to the method specified in Article 1.1 in
20-03-06-402.
— It is recommended that under environment temperature 20℃ and below, the standing
time of clamped assembly should be at least 12 hours(one night)，however，it should be
capable of activating and curing by heating the assembly to 80℃.
1.3 Post connection check (see detail C in Fig.1)
Fit a tested screw (1) on the anchor nut, of which, the diameter shall be in consistence
with anchor nut to be assembled，and use a lock nut in matching to fix the anchor nut on
the screw .
Directly applying a torque to the ribbon type floating anchor nut should not cause
movement of the anchor nut.
—For a fixed ribbon type floating anchor nut：
• Screw with diameter of 5 mm：torque is 0.73+ N.M.
• Screw with diameter of 4 mm：torque is 0.45+ N.M.
Under action by a force (F) to make screw engaged，anchor nut should be free from
movement.
—For the screw provided to the anchor nut：
• For 5 mm diameter, apply 46+N.
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• For 4mm diameter, apply 36+N.

2 Replacement of Damaged Anchor Nut
2.1 Removal of anchor nut (see detail A in Fig.2)
Use a ring drill to cut the stop laminated washer of anchor nut as indicated by arrow F.
Remove and discard the anchor nut.
2.2 Installation of anchor nut (see detail B in Fig.2)
Steps specified in Article 1.2 should be used.
Requirement for operation：
— Fit a new anchor nut at opening (1) where fiber washer previously is fixed, and the
new fiber washer (2) will be used to fix the anchor nut as specified by procedure
— The anchor nut should not be directly connected to the laminar skin (3).
Fig. 1
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Fig. 2
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REPLACEMENT OF “LC” ASN-A0069 SERIES NUT
1 Replacement of “LC” Nut

1.1 Cut a slot suitable for “LC” nut (see detail A in Fig.1)
Use the type LC10 manual slot cutting tool (3) or type LC300 manual slot cutting tool (4)
or use the slot cutting pliers 2A403/Z95 to drill a hole (2) on the cockpit cowling or door
component in accordance with “LC” nut casing diameter +0.2mm, and trim guard ring (6)
of slot (5) LC nut to get ready for installation of nuts.
1.2 Installation of “LC” nut (see detail B in Fig.1)
— Align the lug with slot (1).
— Press down, and then turn it by 1/4 turns so as to be easy in fixing the (2).
— With the purpose that “LC” nut driver (3) can be used when installation is carried out
on a thick part.
Note: Using the nut driver equipped with a proper adapter will be easy in installation.
1.3 Characteristics of “LC” nut (see detail C in Fig.1)
— A toothed washer is formed on the case top, which enables the nut remain fixed v (1).
— Insert plastic filler (2) to ensure an absolute self-locking + sealing.
Fig. 1
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REPLACEMENT OF “CAMLOC”
QUICK RELEASE FASTENER NSA551-30
1 Replacement of “CAMLOC” Quick Release Fastener (Series 4002)

1.1 Replacement of quoit (see detail A in Fig.1)
— Use CAMLOCK4P3 pliers (1), tilt bolts to remove lock bolt (5) through the compression
spring. Never remove the pin at bolt end.
— Pry the fixed ring，and then remove the quoit.
— Use CAMLOCT26 tool (4) to install a new NR4002N quoit (2)，and use NR-R4G fixed
ring (3) to fix it.
— Use CAMLOC4P3 pliers to reinstall the lock bolt.
1.2 Replacement of socket (see detail B in Fig.1)
— Flat the rivet head (1) on the side of formed end.
— Disassemble rivet and socket (2).
— Use two 100°countersunk rivets with diameter of 3.2mm to install a new NR-214-16
socket.
2 Replacement of “CAMLOC” Quick Release Fastener (series 2600 and 2700) (see detail
C in Fig.1)
— Pry 2600-L-W fixed ring (1).
— Remove the lock bolt with help of CAMLOC4P3 pliers.
— Install a new lock bolt (2).
— Install a fixed ring (1) with help of CAMLOCT98-1 tool.
Note: For replacement of sockets，refer to Article 1.2.
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Fig. 1
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REPLACEMENT OF
“DZUS” QUICK RELEASE FASTENER NSA551.10—1 DZUS
1 Replacement of “DZUS” Quick Release Fastener (series 4002)

1.1 Replacement of P31／2 fastener assembly (see detail A—B—C in Fig.1)
— Use P31／2T3 punch (2) and PT31／2B2 stop (3) to remove the pin, spring and cap (1)
— detail A.
— Use PT31／2T1 punch (2) and PT31／2B1 stop (3) squeeze the new PC31／2 cap
(1) — detail B.
— Install a new PF31／2 holding pin (1) provided with a PS31／2 springs (2) in the cap，
and with help of PT31／2T2 and PT31／2B2 stops, squeeze the cap (4) and fix the
pin— detail C.
2 Replacement of “L”HOTELLIER Fastener (see Fig.2)
— This kind of fastener shall use a pair of special pliers (1) to compress the spring for
removal and installation.
— As soon as the fastener is installed, the pin should be located at the inside (2).
Fig. 1
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Fig. 2
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REPAIR OF DAMAGED THREADS
1 Repair of Damaged Threads with Threaded Bush

Caution: For the critical components, this repair method needs to be approved by
manufacturer in advance.
1.1 General
This kind of method is to use a threaded bush inserted piece to replace a damaged thread.
As an advantage，it recovers original dimensions and tolerance of thread using a simple
and cheap method, as a result, to enlarge the dimensions of bolts，stud bolt and the like
can be avoided and prolong the time between overhaul of the repaired assembly.
1.2 Description on HELI-COIL threaded bush
1.2.1 Free threaded bush (see detail A in Fig.1.)
The threaded bush is of a stainless steel or cadmium plated phosphor-bronze metal wire
toothed spring appearance, of which the cross section is like diamond, thus forming a
male thread used for fitting in the part, and a female thread used for fitting the screw.
The threaded bush is inserted into a thread cut hole via its fork tip (1)，and it has the
first turn (2) with a diameter of relatively small，on which the groove (3) is enable the
fork tip to be cut in the through hole，so that the screw can freely pass through the
hole .
There are two kinds of threaded bushes：
— Standard bush as mentioned above.
— Self-locking bush ， which is equivalent to standard bush in principle and
characteristics. It is that one or several torsion rings (4) are included in a standard
bush，and generally it is located at the height of mid thread，and it is sure that the
double lock is arranged on the side of tap thread and on the side of screw. This kind
of thread shall be marked in red，so that it can be visually distinguished from the
standard thread.
1.2.2 Installation of threaded bush (see detail B in Fig.1
A threaded bush can be installed in a through hole (a) or blind hole (b).
Definition of threaded bush that has been installed：
— E：Basic length (the basic length of threaded bush shall be in compliance with the
minimum effective tapped length or minimum thickness of a part, which is denoted
by the multiple of standard diameter D).
— L：Installed length of threaded bush
— R：Maximum length engaged screw in thread (fork tip is uncut - as for the blind
hole).
— S：Depth of hole (if the screwdriver includes 2 or 4 thread pitch inlet chamfers, then
depth is different).
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— N：Minimum available length (used for self-locking thread)

— T：Maximum tapping diameter
— P：Threaded portion is 0.25 to 0.5 thread pitch returned from connecting surface.
— d：Diameter of guide hole
1.2.3 Codes
— Code for threaded bush types
— (dashed line) Standard type (unlocked )
Codes
F Self-locking type
Fig. 1
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— Codes of basic length

Basic Length 0.5D 0.75D 1D 1.5D 2D 2.5D 3D
Codes 050 075 100 150 200 250 300
—Code of material
C Stainless steel
Codes
B Cadmium plated phosphor-bronze
— Coded part No.

Threaded bush coded part includes basic part No.52502 followed by：
• Code of type
• Standard diameter denoted by 1／10mm
• Code of basic length
• Code of material
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1.3 Requirements for installation

It is recommended to use phosphor-bronze bushing. The possibility of installation depends
on holding an effective open surface area around the hole to be repaired.
To fit the threaded bush，a special tool is required，which should vary with diameter of
bushing to be assembled. For a proper operation，the following tools are required.
—One standard tool with mandrel，or one standard tool with pre-wound insert piece.
— One manual fork tip cutting tool.
— Special screwdriver (see page 15 of Z9-J standard-21)
1.4 Installation of threaded bush
1) Drill a lead hole according to the required diameter.
2) Use the screwdriver in compliance with the bushing to be installed for tapping.
3) Use tool to lead in threaded bush：
— The grooved is applicable to through-hole
— The ungrooved is applicable to the blind hole
4) Cut fork tip (used for through hole)
5) Final turn of bushing should be 0.25～0.5 thread pitches lower than connecting surface.
1.5 Table for dimensions
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Thread
Tolerance 2.5 3 4 5 6 7 8 10 12 14 16 8 20 22
Diameter “D”
Thread pitch 0.45 0.5 0.7 0.8 1.00 1.25 1.50
0.50D 9 10 11
0.75D 12 13.5 15 16.5
1D 2.5 3 4 5 6 7 8 10 12 14 16 18 20 22
Basic 1.5 D 3.8 4.5 6 7.5 9 10.5 12 15 18 21 24 27 30 33
Length 2D 5 6 8 10 12 14 16 20 24 28 32 36 40 41
E 2.5 D 6.3 7.5 10 12.5 15 17.5 20 25 30 55
3D 7.5 9 12 15 18 21 24 30 36 42
Threaded Max. 3.5 4.3 5.6 6.8 8.0 9.1 10.4 12.6 14.9 17.2 19.5 21.8 24.1 26.3
Bush OD
“A” Min. 3.5 4 5.15 6.35 7.6 8.65 9.85 21.1 14.4 17.2 19.4 21.5 23.7 26.3
Thread hole
Lead Hole d
2.6 3.2 4.2 5.2 6.3 7.3 8.4 10.5 12.5 14.5 16.5 18.5 20.5 22.5
Diameter
0.5 D 14 15 6 17
Blind 0.75 D 18 19.5 21 22.5
Hole 1D 4.3 5 6.8 8.2 10 1l 13 16 18 20 22 24 26 28
Min 1.5 D 5.6 6.5 8.8 10.7 13 14.5 17 21 24 27 30 33 36 39
Depth 2 D 6.8 8 10.8 13.2 16 18 21 26 30 34 38 42 46 50
S 2.5 D 8.1 9.5 12.8 15.7 19 21.5 25 31 36 41
3D 9.3 11 14.8 18.2 22 25 29 36 42 48
Max. Tapping
3.1 3.7 4.9 6.1 7.4 8.4 9.7 12.1 14.1 16.1 18.1 20.1 22.1 24.1
Diameter T
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Fitted Bush
Thread
Nominal 2.5 3 4 5 6 7 8 10 12 14 16 18 20 22
Diameter D
0.5 D 6.5 7.5 8.5 9.5
L 0.7 D 10.5 12 13.5 15
Max. 1D 2 2.75 3.65 4.6 5.5 6.5 7.37 9.25 11.25 11.25 15.25 17.25 19.25 21.25
length 1.5 D 3.3 4.25 5.65 7.1 8.3 10 11.37 14.25 17.25 20.25 23.25 26.25 29.25 32.25
of fitted
2D 4.5 5.75 7.65 9.6 11.5 13.5 15.37 19.25 23.25 27.25 31.25 35.25 39.25 43.25
bush
2.5 D 5.8 7.25 9.65 12.1 14.5 17 19.32 24.25 29.25 34.25
3D 7 8.75 11.65 14.6 17.5 20.5 23.37 29.25 35.25 41.25
“N” 1D 5.5 7.0 7.8 9.5 12.5 14.3 15.3 16.3

Min.
available 1.5 D 3.2 3.8 5.1 6.2 7.0 8.8 9.8 12 13.5 15 16.5 18.8 20.3 21.8
self 2D 4.5 5.3 7.1 8.7 10 12.3 13.8 17 19.5 22 24.5 27.8 30.3 32.8
locking 2.5 D 4.4 5.3 7.1 8.7 10 12.3 13.8 17 19.5 22
length
3D 5.7 6.8 9.1 11.2 13 15.8 17.8 22 25.5 29
“R” 0.5 D 5.8 6.8 7.8 8.8

Max.
screw 0.75D 9.8 11.3 12.8 14.3
length lD 1.8 2.3 3 3.8 4.5 5.5 6.1 7.8 9.8 11.8 13.8 15.8 7.8 19.8
engaged 1.5 D 3.1 3.8 5 6.3 7.5 9 10.1 12.8 15.8 18.8 21.8 24.8 27.8 30.8
in blind
2D 4.3 5.3 7 8.8 10.5 12.5 14.1 17.8 21.8 25.8 29.8 33.8 37.8 41.8
hole
2.5 D 5.6 6.8 9 11.3 13.5 16 18.1 22.8 27.8 32.8
3D 6.8 8.3 11 13.8 16.5 19.5 22.1 27.3 33.8 39.8
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REPLACEMENT OF “VELCRO” TAPE
1 Replacement of “VELCRO” Tape

“VELCRO” fastener is comprised of two 100％ nylon braided tape, that is, scotch tape
and bridle .
The pressure applied to two tapes is enough to obtain an effective adhesion force for
bearing any lateral, transverse or longitudinal tension , VELCRO tape shall be supplied as
per 15～50 mm in width or according to the order.
In general，scotch tape (1) is preferred to be installed on the fixed part (2)，bridle (3)
installed on the removable part (4).
2 Installation of “VELCRO” Tape
2.1 Bridle (see detail B in Fig.1)
Fixed tape should be laced up to bearing material (plywood).
Caution: It is not allowed to use small sized nail.
2.2 Seaming (see detail C in Fig.1)
It is recommended to use the nylon wire (1)，so as to prevent the seaming wire from being
worn faster than the tape.
On the edges, “VECRO tape” will correctly fixed using double continuous seaming wires.
Except that it is completely impossible，the single should be avoided. It is recommended
to use the laterally adjustable trimming squeezer foot seat to seam VELCRO tape.
2.3 Bonding (see detail D in Fig.1)
The tape can be bonded to majority of materials. Before bonding the tape，it is required to
clean the material surface.
— On the fabric, generally use polychlorobutadiene adhesive agent.
— On the aluminum, iron, vinyl chloride，use VELCR040 or EC1917 adhesive for
bonding .
It is recommended to use the adhesive agent EC2216 on the laminated parts.
Important notes：
— VELCRO adhesive
• Sensitive to copper solvent
• Storage life：It is 12 months in the original container with temperature of 20℃.
• Operation and storage should be far away from open fire.
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Fig. 1
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REPAIR OF TRANSPARENT MATERIALS
1 Repair of Transparent Materials

1.1 General
This task card includes cleaning up the scores on Plexiglas and repairing cracks.
1.2 Cleaning up the scores (see Item 1 in Fig.1)
— Use water proof abrasive paper (select grit 280 or 400 depending on degree of scores)
to sand the scores. The abrasive paper should be wrapped on the wood block covered
with soft flannelette, or wrapped on the hard rubber block in operation.
— After cleaning up completely the scores, use 600# grit water proof abrasive paper for
sanding，and in sanding, it is required to enlarge the remachining area and in cross 90°
with direction of scores .
— With absorbent cotton medical grade A)，or cotton flannelette applied with Plexiglas
polishing compound，polish Plexiglas surface in circular motion mode or in alternate
directions. In the polishing operation, the Plexiglas should always be kept wet，and
after it is polished to the required transparency，wipe clean residual polishing
compound using a clean soft flannelette.
1.3 Repairing cracks
1.3.1 Drilling crack-arrest hole (see Item 2 in Fig.1)
— Drill a crack-arrest hole with diameter of 3mm at the end of crack.
— For star shaped crack，likely, drill a crack-arrest hole at the end of each crack.
1.3.2 Use a proper Plexiglas stiffening plate to repair cracks (see Item 3 in Fig.1)
— Drill a crack-arrest hole at the end of crack.
— From a Plexiglas sheet, cut a sticking patching that can cover cracked area.
— Heat the sticking patch in heating box to 20 -140℃，and form as per the appearance
of the repairing position.
— Cooling the sticking patch, the formed plate should be slowly and uniformly cooled
in die, until temperature of part surface drops to 40℃ and below.
— The bonding surface must be wiped using clean absorbent cotton dipped with patrol
(120#)，or use 3～5％ neutral soap water for cleaning. Finally rinse with clean
water and dry it.
— Uniformly apply a acrylic resin glue (SYT-1, etc)，or Plexiglas adhesive agent to
each bonding surface. It is required to try as much as possible to shorten the glue
applying time to prevent formation of air bubbles or foams. The glued surface
should be held for a period of time under temperature of 20-25℃，so that the
adhesive agent can reach a appropriate thickness and without loosing viscosity.
— Fit the sticking patch in a repair area，and lightly apply pressure until the proper
adhesive force is obtained.
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1.3.3 Use proper aluminum alloy stiffening plate to repair cracks (see Item 4 in Fig.1)
— Drill a crack-arrest hole as per method in Article 1.3.1.
— Check central holes，of which the sizes should be sufficient to pass screw with
diameter of 4mm，otherwise, it should be drilled to 4.2mm. In drilling, the
temperature of neither drill bit nor Plexiglas should not exceed 40℃.
— Cut two pieces of liner s made of 5052(A-G3) material，and these two pieces of
liners will be used to cover the main holes in the center of star shaped crack
— Use EC 870# adhesive agent to bond a 3mm thick rubber seals on these liners.
Drill a 4.2 diameter hole at the center of liner，and then use EC 870# adhesive agent to
bond two liners respectively on the inside and outside Plexiglas，and use a 4mm
diameter screw , washer and nut to connect the assembly.
— Drill equidistant alternative holes with diameter of 1.5mm（pitch=10mm）at the place
about 4 mm from edges of crack，and use nylon rope to bind two rows of holes .
— In order to ensure the tightness of repair，stick the transparent adhesive tape paper to
the bonding area.
Fig. 1
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REMOVAL OF SCRATCHES USING ABRASION

POLISHING METHOD
1 Removal of Scratches Using Abrasion Polishing Method

1.1 General
The main point of the burnishing is s surface cold work which produces compression
stress. The burnishing is to use a very hard and unsharp tool to pressurize the edges to be
polished to perform cold working，i.e. burnish working.
1.2 Purpose
Burnishing can be use to remove scratches on skin board，or used to improve the fatigue
strength of part edges due to machining (e.g. countersunk hole or non-countersunk hole
with diameter of 14mm and below 14mm，and for the holes with diameter of exceeding
14mm，spot face fillet of hole root，bore hole chamfer ).
1.3 Precautions to be taken
The burnisher should not be pressed to much to prevent occurrence of burrs to indicate
cold work coefficient has exceeded the allowable limit，because under this condition，the
effect of burnishing is destroyed.
Keep the burnisher and parts free from dust，metal chips or pollution of any lapping agent.
Never work nearby the emery wheel. When conducting burnishing with burnisher，eyes
should always watch the burnisher，and keep it clean. Use compressed air to clean up and
sand blast holes to be burnished，remove any metal chips or debris.
1.4 Removal of scratches on light alloy skin boards
1.4.1 General
The so called surface defect refers to scratches and indentation on various parts in
contact with skin boards.
1.4.2 Method to remove scratches (see detail A in Fig.1)
It is recommended that the tool to be used is a 40mm diameter circle made of 4mm
chromium plated (1) burnisher handle (2)， .
Caution: It is prohibited to use emery cloth, scraper or other methods related to
the cutting.
1.4.3 Operation of burnishing (see detail B in Fig.1)
— For convenience of sliding of the tool，apply grease to the surface to be reprocessed.
— Operate burnisher along the longitudinal direction of scratches，so as to burnish the
cold worked (1) bottom.
— Carry out this work on either side of the scratch，so as to smooth the scotched
surface (2)，thus forming a cold working area (3).
1.4.4 Refined surface parts
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— After burnished，use trichloroethylene to clean grease of surface to be reprocessed.

The treated area by using this kind of method will be glossy and slightly in black.
— burnisher marks can be removed using polishing agent and according to the
treatment method specified in task card 20-04-03-403 in Standard Practices Manual.
1.5 Removal of scratches on parts with rough edges (see Fig.2)
The manual burnisher (1, 2) is made of 16NCD-13 steel by lathe，and it is subject to light
polishing，surface hardening，quenching，re-polishing，and chromium plating. It can also
be made of nitrated steel.
Straight manual burnisher (1) has headers with diameter of 2 mm, 3mm or 4mm.
Fig. 1
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The bent hand burnisher (2) has a 4mm diameter header.

Burnisher (3) mounted on machine is straight rod with semispherical end. The diameter of
end should fit in with diameter of hole.
Actually the operational check is always a visual check，because the burnishing will
generate a particularly smooth surface
Relationship between “D” diameter value and hole diameter
Hole diameter 4 5 6 8 10 12 14
Non-countersunk hole 6 7 8 11 14 17 20
“D” Countersunk hole
5 6 7 9 11 14 16
(90°，100°，120°
1.6 Operation pf burnisher mounted on the machine.

This type of burnisher is widely used for countersunk hole or non-countersunk hole.
The burnisher can be installed on either fixed machine or on a hand drill.
In any cases，the rotating speed shall not exceed 150 rpm，because the burnishing is short
operation，about 10 turns are sufficient, which is equivalent to a rotating speed 150 rpm
for 4 seconds. In order to use the hand drill for burnishing，never hold the hand drill at
standstill along the hole axle，but on contrary, provide a circumferential movement in low
amplitude while lightly pressing it.
After completion of burnishing by machine, sharp edges are become chamfer of 2/10 to
3/10mm.
Note: Never burnish a dry surface; it is required to lubricate using a plain lubricant.
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Fig. 2
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REPAIR OF DIMPLING CRACKS
1 Repair of Dimpling Cracks

No matter how is the position of metal sheet，any cracked dimpling should be under the
condition as specified below，and use a cup shell (concave washer) to replace it. For the
internal or external metal sheet，the rivet head or tail should cling to supplementary
Z3CN18 or Z10CNT18 stainless steel cup shell.
1.1 Definition of cup shell (see Fig.1)
1.1.1 Cup shell for replacement the cracked dimpling
These cup shells (1) should be made of light alloy that has the same property and
thickness as that of metal sheet of cracked dimpling (3).
1.1.2 Auxiliary cup shell
These cup shells (2) are made of Z3CN18 or Z10CNT18 stainless steel，and the
thickness of steel sheet is 3／10mm.
1.2 Repair
Table 1—When repairing rivet cracked dimpling，it is required to be in compliance with
limits of dimensions.
(For the requirement of diameter，refer to Fig.1)
Diameter of Hole to
Diameter of Hole Diameter of
Diameter Diameter of be Reamed from
Obtained through Light Alloy
of Stainless steel Diameter A to
Drilling or Cup Shell
Rivet to Cup Shell (2) Diameter D for
Stamping (1) (Diameter:
be Fixed (Diameter: C) Assembly of Light
(Linear Length: A) B)
Alloy Cup Shell
-0 0 0 -0.3
φ2.4 φ8.5 φ9 φ12 φ9
+0.2 -0.1 -0.1 -0.35
-0 0 0 -0.3
φ3.2 φ9.5 φ10 φ13 φ10
+0.2 -0.1 -0.1 -0.35
-0 0 0 -0.3
φ4 φ10.5 φ11 φ14 φ11
+0.2 -0.1 -0.1 -0.35
-0 0 0 -0.3
φ4.8 φ11.5 φ12 φ15 φ12
-0.2 -0.1 -0.1 -0.35
1.2.1 Hole to be drilled or stamped

Cracked dimpling shall replaced with one hole （φA）, which is made by drilling or
stamping，and is 5/10mm smaller than the diameter of light alloy cup shell（φB）
（see the
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reference tables）.
1.2.2 Reaming
Ream a hole to make its diameter to fit in with cup shell (Reference table 1).
1.2.3 Installation (see Fig.2)
Detail A：
a—Defect：Cracked dimpling (1) located on the interface layer sheet (2).
b—Repair：Fix the PRl221B bonded filling cup shell in the drilling area (4)，rivet by
using a standard rivet (6) .
Detail B：
a—Defects：Cracked dimpling (1) is located on the outer layer plate (2).
b—Repair： Fix the PRl221B bonded filling cup shell (3) in the area (4) to be drilled.
Install a steel cup shell (5)，and then rivet by using a standard rivet (6) .
Detail C：
a—Defects：Cracked dimpling (1) is located on the inner layer plate (2).
b—Repair：Fix the PRl221B bonded filling cup shell (3) in the area (4) to be drilled.
Install a steel cup shell (5)，and then rivet by using a standard rivet (6) ..
Detail D：
a—Defects：Cracked dimpling (1) is located on the sheet (2) with dimpling hole.
b—Repair：Fix the PRl221B bonded filling cup shell (3) in the area (4) to be drilled.
Install a steel cup shell (5)，and then rivet by using a standard rivet (6) .
Fig. 1
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Fig. 2
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PRINCIPLE FOR REPAIR OF CRACK-ARREST HOLES
1 Principle for Drilling and Repairing of Crack-Arrest Holes

It seams meaningful to give some simple examples as follows which are applicable to
various kinds of moderate cracks or flaws within the standard repair limits without wide and
expensive removal.
A damaged part is possibly located in inside or outside any structure assembly, and the
following examples are provided to repair personnel in operation and different kinds of
solutions are also given to them as many as possible..
1.1 Principle for drilling crack-arrest holes
On nay structure members, as soon as a crack is found, no matter in whichever area it is
located, it is recommended to use the following methods to stop the growth of crack：
— Drill a hole with diameter of 2.4 or 5mm at each end of the crack (which depends on
thickness of the damage part), and carefully remove burrs from holes.
— Based on extent and position of crack (on the main or non-essential part), the radical
repair of damage part should be performed as soon as possible.
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REPAIR OF CRACKS ON SHEET-METAL PARTS
1 Repair Method of Cracks on Sheet-Metal Parts

1.1 Equipment Required
1.1.1 Tool
— General tool.
— Manual scissors.
— Pneumatic drill.
— Riveting press.
— Drill bit.
— Pneumatic rivet gun.
— Spray gun.
— Scraper or squeezing gun.
1.1.2 Material
— Alodine 1200.
— Trichloroethylene or methyl ethyl ketone (MEK).
— Ethylgroup acetate (ethyl acetate).
— XM-22B or French material PRl221B sealing compound.
— Coating compound (use the coating compound as specified in the Structure Manual).
1.1.3 Spare parts
— Metal sheet.
— Ordinary head rivet as required by repair position.
1.2 Initial stage
— Remove all components adjacent to repair area，which is necessary for easier to
remove rivets and carry out the riveting.
1.3 Steps (see Fig.1)
1.3.1 Preparation for locating face and stiffening plate
— Check for initial cracks around the existing rivet holes.
— Drill a crack-arrest hole of about 2mm diameter at each end of crack.
— Cut a stiffening plate of proper shape and size from a metal sheet with the same
thickness as that of cracked sheet-metal part.
— Form the stiffener as described in 20-02-03-403 and according to the outline of
repair area.
— According to the ready-made rivet, lead the rivet to the stiffening plate，and ensure
the requirements for repaired edge distance while cutting and trimming the
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stiffening plate.
— Drill several locating holes so as to position the stiffening plate on the locating face.
— Locate the stiffening plate，then fastened to the locating face.
— Drill a hole according to the existing rivet hole -- through-hole from the hole on
locating face through to stiffening plate.
— According to the graticule on the stiffener (new rivet)，drill hole on the locating face
and stiffening plate.
— Remove stiffening plate.
— Remove burrs of holes and chamfer sharp edge of stiffener.
—Remove the metal chips caused by drilling.
1.3.2 Cleaning and checking
— Use trichloroethylene to clean the locating face.
— Check for corrosion marks, and remove the rust as specified in 20-04-03-401 in the
Standard Practices Manual.
— Check if there are initial cracks (hair cracks) on metal sheet (1)，stringer (2) and
bulkhead flange edge (3) with locating faces，and around existing rivet hole.
— Check all rivets of repair area，and remove loosened and cracked or deformed rivets.
— If necessary，trim the repair area.
— Determine the rivets to be used by taking the diameter of hole into consideration：
• Standard size rivet.
• Oversized rivet.
1.3.3 Surface treatment and protection treatment of locating face and stiffener
— According to the description in task card 20-04-04-403 in Standard Practices
Manual, carry out the surface treatment on stiffener (4) using Alodine 1200.
— According to the description provided in task card 20-04-05-101 in Standard
Practices Manual，use a coat of paint to protect the surface of stiffener.
— If necessary, repeat the above operations on locating face.
1.3.4 Installation
Practices Manual, apply a thin coat of PR1221BorXM-2213 sealing compound to
the skin part.
— Directly locate and fix stiffening plate on wet sealing compound.
Note: The stiffening plate fixed on the structure with wet sealing compound is very
loose.
— Installation of rivet (For rivet with diameter of 3.2mm，use pitch of 13～35mm).
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Notes on Rivet:
-1- Unused rivet hole.
-2- Pitches arranged according to existing rivet holes.
-3- New rivet.
— Trim the outer coat of paint as specified in task card 20-04-05-701 in the Standard
Practices Manual.
Fig. 1
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REPAIR OF FLANGE AND SKIN CRACKS
1 Repair of Cracked Flange (see detail A area in Fig.1)

Material with the same thickness as that of repair area should be used to repair cracked
flange.
Rivet pitch should be determined as per the rivet diameter.
2 Repair Scratches and Cracks on Skin (see detail B in Fig.1)
After a 4mm diameter crack-arrest hole at the end of scratch or end of crack being drilled,
deep scratch (1) and cracks (2) should be repaired by adding an external stiffening plate (3),
the material of stiffening plate and thickness of the material will depend on area to be
repaired.
A chamfer should be made in the perimeter around stiffening plate.
Stiffening plate should be riveted in accordance with rivet pitch of area to be repaired using
AVDEL general head rivet or using GB869-76 rivet with diameter of 3.2 or 4mm, and
applying XM-22B or France material PR1221B sealant to assembly.
Fig. 1
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REPAIR OF SKIN CRACKS
1 Repair of Skin Cracks (see Fig.1)

A 4mm diameter hole should be drilled at end of crack with maximum length of 50mm on
skin (1), and after that, repair will be made by adding internal and external stiffening plate
(3 and 2) with the same thickness as that of cracked skin.
Chamfer (4) should be made in the perimeter around stiffening plate.
Stiffening plate should be riveted as required using round head rivet GB1011-76 or 120°
head rivet GB954-76, and applying XM-22B or France material PR1121B sealant to
external stiffening plate (3) assembly.
Fig. 1
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REPAIR OF SKIN CRACKS BETWEEN STRINGERS
1 Repair of Skin Cracks between Two Stringers (see Fig.1)

Skin cracks between two stringers (1) should stop crack growth by using washer (2), and
add inner and outer stiffening plates (3 and 4) to repair.
Install 16mmdiameter washer with the same thickness as that of cracked skin into trim area
(5) of having the same diameter.
Chamfer (b) should in the perimeter around internal and external stiffening plates, and
stiffening plate thickness should be the same as that of cracked skin.
Stiffening plate and washer should be riveted as required using round head rivet GB1011-76
or 120° head rivet GB954-76, and applying XM-22B or France material PR1121B sealant to
stiffening plate assembly.
Note on Rivet：
1— New rivet hole.
2— Take rivet hole in accordance with original rivet hole.
3—Rivet holes not subject to repair.
Fig. 1
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REPAIR OF SKIN CRACK ON

STRINGERS NOT CONNECTED WITH SKELETON
1 Repair of Skin Crack on Stringer Not Connected with Rib or Skeleton (see fig.1)
Crack-arrest hole should be drilled at each end of deep scratch or crack (3) on skin plate of
stringer not connected with rib or skeleton, and A-U4G1 P1-A5 external stiffening plate
with the same thickness or slight thicker than original skin will be used and bonded by
means of PR adhesive.
Chamfer should be made in the perimeter around stiffening plates
Stiffening plate should be riveted using 3.2 or 4mm diameter general head rivet (6)or rivet
with original rivet diameter, as well as 3.2 mm diameter general head AVDEL rivet (6) or
rivet GB954-76 and applying XM-22B or France material PR1221B sealing compound to
the assembly.
Fig. 1
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REPAIR OF SKIN ON SKELETON BETWEEN STRINGERS
1 Repair of Skin on Skeleton between Two Stringers (see Fig.1)

A crack-arrest hole should be drilled at each end of deep scratch or crack (3) on skin plate (5)
on skeleton (1) between two stringers (2), and one external stiffening plate with the same
thickness and same material as that of skin to be repaired should be added .
A chamfer should be made along the perimeter of stiffening plate.
The rivets to be used should be the completely the same as the rivets removed. For existing
rivet holes, the rivet pitch should be previous rivet pitch.
Note on Rivet：
1—Rivet holes not to be repaired.
2—Rivet holes arranged in accordance with the existing rivet hole pitch.
3— New rivet holes.
Adhesive PR1221B should be applied to stiffening plate assembly.
Fig. 1
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REPAIR OF SKIN ON SKELETON AND STRINGER AT SKIN JOINTS
1 Repair of Skin on Skeleton and Stringer at Joint of Two Skin Plates (see Fig.1)
A crack-arrest hole should be drilled at each end of deep scratch or crack on skin plate (5)
on skeleton (1) and stringers (2) at joint of two skin plates, and one external stiffening plate
(4) with the same thickness and same material as that of skin and one gasket (6) should be
added. Apply XM-22B or France material PR1221B sealing compound to the area between
stiffening plate and skin.
The rivets to be used should be the completely the same as the rivets removed. When rivet
holes are as per the existing rivet holes, pitch should be the same as the previous pitch. As
for 3.2mmdiameter and new rivets, pitch should be 13mm.
Note on Rivet：
1—Rivet holes not subject to repair.
2—Rivet holes arranged in accordance with the existing rivet hole pitch.
3— New rivet holes.
Fig. 1
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REPAIR OFCRACKS AT RIVETED PLACE ON SKELETON FLANGE
1 Repair of Cracks at Riveted Place on Skeleton Flange (see Fig.1)

A crack-arrest hole should be drilled at each end of crack (1) at riveted place on skeleton
flange, and a LY12BCZ stiffener (2) should be added, of which the thickness should be
determined as per skeleton. Apply XM-22B or France material PR12281 sealing compound
to the area between stiffener and flange as well as that between stiffener and skin (4).
The pitch should be the pitch of original skeleton on skin.
Fig. 1
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REPAIR OF HOLES ON SHEET-METAL PARTS
1 Repair of Holes on Sheet-metal Parts

1.1.1 Tools
— Standard tool.
— Pneumatic drilling.
—Pneumatic riveting gun or riveting gun used by AVDEL rivets.
— Recessed pushing iron.
— Holing tool.
— Riveting press.
— Drilling bit.
1.1.2 Materials
— Trichloroethylene
— Methyl ethyl ketone (MEK) (Ketone)
— Alodine 1200.
— Coating (as per coating specified in the Structure Repair Manual).
1.1.3 Spare parts
— Metal sheet (refer to Chapter of “Identification of Materials”).
— General purpose rivets determined as per position to be repaired.
1.2 Preparation
— If necessary，remove structural members from repair area .
1.3 Procedures
1.3.1 Preprocessing the locating face and stiffener
1) With help of holing tool, remove faults of damaged sheet-metal part.
2) Trim repair area.
3) Remove burrs and grind sharp edges.
4) Cut the following repaired parts from metal sheets with the same material and
thickness as that of locating face；
a) Gasket: Diameter of this part should be equal to or little less than the diameter of
hole, which can be riveted or bonded.
b) Stiffener: Size of stiffener depends on quantity and shape of rivets.
5) According to the description provided in task card 20-02-04-601 in Standard
Practices Manual, arrange the position of rivet.
6) Position the stiffener and fix it to skin, and then drill the rivet hole.
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7) Remove the stiffener.

8) Remove burrs from rivet hole, and clean up metal chips caused by drilling holes.
1.3.2 Clean and check
— Use trichloroethylene to clean the locating face.
— Check for corrosion marks, and remove the corrosion mark as specified in
20-04-03-401 in the Standard Practices Manual
— Check if there are initial cracks on locating face skin (1), stringer (2) and frame
flange (3) (see Fig.1 in task card 20-03-05-405) bulkhead flange edge (3) around
existing rivet holes.
— Check all rivets of repair area，and replace loosened, cracked or deformed rivets.
— If necessary，trim the repair area.
— Determine the rivets to be used by taking the diameter of hole into consideration：
• Standard size rivet.
• Oversized rivet.
1.3.3 Surface treatment and protection treatment of locating face and stiffener
— According to the description in task card 20-04-04-403 in Standard Practices
Manual, carry out the surface treatment on the base plate and stiffener using
Alodine 1200.
Practices Manual，use paint specified in the Structure Repair Manual to paint the
treated part , and if necessary, paint locating face.
1.3.4 Installation
1) Locate, fix and rivet a stiffener.
2) Clean stiffener and faying surface of the base plate.
3) Bond a base plate of stiffener，clean up extra bonding agent，or fit rivets.
4) Trim the outer coat of paint as specified in task card 20-04-05-701 in the Standard
Practices Manual.
1.4 Final step
— Installation all structural members nearby the repaired area.
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REPAIR OF HOLES ON FUSELAGE INTERNAL STRUCTURE
1 Repair of Holes on Fuselage Internal Structure

1.1 Repair with single-raw rivet (see detail A in Fig.1)
The damaged area (1) should be covered with a cover plate (2) of having the same
material and thickness as that of repair area, which should be so big to ensure the rivet
edge distance L is equal to or more than 7mm.
Rivet (3) to be used should be AVDEL rivet standard rivet with diameter of 32.
The pitch should a standard pitch to be determined by rivet diameter.
A chamfer should be made along the perimeter of stiffening plate.
1.2 Repair with double-raw rivet (see detail B in Fig.1)
Repair method is completely the same as that of single-raw rivet. The cover plate sizes
should allow for double-raw rivet, and the spacing of such double-raw rivet should be half
of the standard rivet pitch (P/2).
Fig. 1
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REPAIR OF HOLES ON FUSELAGE EXTERNAL STRUCTURE
1 Repair of Holes on Fuselage External Structure

1.1 Cracks of less than 25mm (see Fig.1)
The flaw with length of about 25mm on the external skin board (1) or driving device deck
(1) should be repaired by opening a 35mm hole on skin, fitting a 34mm base plate (2) and
adding a stiffening plate (3). Gasket and stiffening plate should be made of LY12BCZ，
and should have the same thickness as that of skin. A chamfer of 0.5 mm should be made
on gasket and flange, and it should be assembled using XM-22B or French material
PR1221B (5) sealing compound，and ensure the maximum clearance between gasket and
Monel skin is 0.5mm.
As required，use a cup head rivet HB6230 or 120° countersunk rivet HB6305 to rivet as
shown in figure. The assembly will be applied and filled with PR1221B sealing
compound.
It is required to use 4 rivets equidistantly fix a gasket to the stiffening plate on circle with
diameter of 20mm
Note: On the titanium driving device deck area, the repair should be performed using the
same material and steel or Monel alloy rivets
The repair method shown in Fig.1 is an external view.
1.2 Cracks of more than 25mm (see Fig.2)
Flaw of longer than 25mm on skin between two stringers or driving deck (1) should be
repaired by filing an area (2) as per flaw，and provided with a cover plate (3)，which
should be sized to make sure 0.5mm maximum assembling clearance (4)，and adding a
stiffening plate (5).
cover plate and stiffening plate should be made of LY12BCZ material，and should have
the same thickness as that of skin.
As required, use a cup head rivet HB6230 or 120° countersunk rivet HB6305 to rivet as
shown in figure. The assembly will be applied and filled with PR1221B sealing
compound. The edge distance of rivet should be equal to or more than 7mm.
Pitch P should standard pitch according to diameter of rivet.
The repair method shown in Fig.12 is an internal view.
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Fig. 1
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Fig. 2
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REPAIR OF CRACKS ON FLOOR BETWEEN STRINGERS
1 Repair of Cracks on Floor between Two Stringers (see Fig.1)

Cracks on floor between two stringers Repair two should be repaired in a way that a hole
will be made on plate (3), the diameter of the hole should be so big that the rivet raw for
fixing the stiffening plate (1) is 10mm from area where the hole is made, and there is 1mm
gap (4) between stiffening plate and stringer edge. Use epoxy resin J-84 to bond the filler
plate (2) with the same diameter as that of the hole made area to the stiffening plate.
The thickness of material used for repair should be the same as that of material of the area
to be repaired.
90° countersunk rivet HB6305 should be used for riveting, and the pitch should be between
minimum pitch and average pitch 3.0mm diameter rivet.
Fig. 1
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REPAIR OF SKIN HOLES ON STRINGERS
1 Repair of Skin Holes on Stringer

1.1 Repairing has no influence on the rivet line of stringer (see detail A in Fig.1)
After opening holes on plate, fit epoxy resin J-84 bonded (1)，as shown in Fig. A，internal
stiffening plate should be riveted on the skin，and clearance (3) of 1 to 2mm should be left
between the flange of stiffening plate and stringer，so that XM-22B or French material
PR1221B sealant can form a sealing adhesive bead along flange of stiffening plate.
Material should be the same type and thickness as that of the material area to be repaired.
Pitch should depend on the diameter of rivet and stiffening plate to be used.
1.2 Repairing has an influence on the rivet line of stringer (see detail B in Fig.1)
After removal of rivets to be repaired and required to be disassembled，open a hole in the
holing area，filler plate (1) and internal stiffening plate (2) are installed together，the
diameter size of stiffening plate should be enough to ensure the edge distance of rivet is at
least 8mm；
Material used for repair should be the same type as that of area to be repaired and the
filler plate should have a thickness equal to that of the skin, and the stiffening plate should
be thinner than the skin. In assembling, epoxy resin J-84 should be used to fill the gap.
The rivet used should be the same as those rivet removed.
Fig. 1
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Fig. 1
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REPAIR OF HOLES ON SKIN BETWEEN STRINGERS
1 Repair of Holes on Skin between Stringers (see Fig.1)

Holes on skin between two stringers should be repaired by using the existing skin rivet hole
on the stringer to add one stiffening plate (3), and the pitch of new rivet is dependant on the
rivet to be used, which should be between the minimum pitch and maximum pitch, and
rivets to be used, should be those rivets used in repair area.
In assembling, XM-22B or France material PR122B1 sealing compound should put in and
applied to the perimeter of the stiffening plate.
Type and thickness of material to be used should be the same as that of material of repair
area.
Fig. 1
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REPAIR METHOD OF METAL SHEET

CRACKS AND HOLES AT SUNKEN AREA
1 Repair of Metal Sheet in Sunken Area

This repair method is used for repair of protruded frame plate or lower frame member on
the aircraft bottom structure.
1.1 Repair of cracks (see detail A in Fig.1)
After cleaning up the damaged part (3) in the repair area, rivet two stiffening plates (1) of
the same thickness onto both surfaces of web (2), and apply XM-22Bor France material
PR1221B sealing compound to each surface of the assembly.
The rivet pitch will be determined in accordance with rivets to be used.
1.2 A stiffening plate is installed in cracked area (see detail B in Fig.1)
After drilling a crack-arrest hole at each end of the crack, rivet stiffening plate (1) of the
same material and same thickness above the cracked area.
Fig. 1
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REPAIR METHOD OF SCRATCHES, CRACKS, PUNCTURES

OF SECTION MATERIAL
1 Scope of Repair
It can be applicable to basic equipment and specified procedure required in 20-02-05-405
and 20-02-05-413 in the Standard Practices Manual.
1.1 Repairing the extruded angle section of the same or different flanges (see detail A in
Fig.1)
After cutting the damaged bar section area，use the bar section that is the same as the
original bar section as filler (2). Use the original bar section to machine into the reinforced
part (3).
The pitch of rivet shall be determined according to length of stiffener and rivet diameter，
but the pitch between the first rivet and flange must be 8mm. After repaired, it should be
as shown in Fig. (4).
1.2 Repairing the bent angle section (see details B-C in Fig.1)
In case it is torn (detail B)，use a reinforced angle section (1) to carry out repairing. The
reinforced angle section should be made and machined using the originally used bent
angle section.
Rivet pitch should be the connecting distance from angle section to sheet (2).
In case it is damaged more severe (see detail C in Fig.1)，it is required to make and rivet a
stiffening plate (3) with the same thickness as that of the angle section .
1.3 Repairing the T-shaped angle section (see detail A in Fig.2)
After cutting the damaged bar section area (1), use the bar section that is the same as
T-shaped bar section as filler (2). Stiffener (3) will be installed on both sides of T-shaped,
which should be L shaped angle section and machined into different lengths, and one
stiffener should be two rivet holes more than other stiffener.
The pitch of rivet shall be determined according to length of stiffener and rivet diameter，
but there mist be distance of 8mm between the first rivet and flange.
1.3.1 Repairing the flange of T-shaped angle section (see detail B in Fig.2)
After removal of the damaged area (1), it can rivet the reinforced filler (2) made of the
same material together with stiffener (3) machined of bar section as required.
The pitch of rivet shall be determined according to rivet diameter and length of
stiffener，but and there must be distance of 8mm from the first rivet to flange.
1.4 Repairing the bent part
1.4.1 Repairing the cracks (see detail A in Fig.3)
A 4mm diameter crack-arrest hole should be drilled for the crack (1) on bent U-shaped
bar section, an then be repaired by adding stiffener (2) with the same thickness as that
of bar section to be repaired.
The pitch of rivet can be determined according to rivet diameter and length of stiffener
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and the rivet position of 8mm from the edge

1.4.2 Repairing damaged parts (see detail B in Fig.3)
After removal of damaged area (1) from the damaged bent channel shaped bar section,
carry out repair, and method of repair is as follows: Fit the reinforced filler (2) and the
internal and external stiffeners (3) and (4) with the same thickness as that of bar section
to be repaired.
The pitch of rivet shall be determined according to rivet diameter and length of
stiffener，and there is distance of 8mm from the first rivet to flange.
1.4.3 Repairing single sided damaged parts (see detail A in Fig.4)
With damaged part (1) removed, the repair work includes riveting a stiffener (2) that is
sufficiently sized to have the same thickness as that of bent bar section.
Determine the rivet pitch as specified in Section 1.4.1.
1.4.4 Butt joint of two channel-shaped pattern plate (see detail B in Fig.4)
After the butt joining of two channel-shaped bar sections end to end，they should be
fixed together using a bent bar section (2) that is connected with bar section and the
same in the internal and external dimensions.
The pitch of rivet shall be determined according to rivet diameter, length of bar section
(2) and ensure there shall be a distance of 8mm from the first rivet to flange.
Legends:
1：Trimmed rivet holes
2：Holes independent of repair
3：New rivet holes.
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Fig. 1
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Fig. 2
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Fig. 3
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Fig. 4
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REPAIR METHOD OF CRACKED AND PUNCTURED

SKIN AND DAMAGED SECTION MATERIAL
1 Repair of Punctured Skin and Damaged Section

1.1.1 Tools
— Standard tool
— Riveting press
— Pop riveting
— Pneumatic drill
— Pneumatic riveting gun
— Drill bit
— Dye penetration test tool
1.1.2 Materials
— Trichloroethylene
— Methyl ethyl ketone (MEK) (Ketone)
— Alodine 1200.
— Coating (as per coating specified in the Structure Repair Manual).
1.1.2 Materials
— Alodine 1200
— Trichloroethylene or ethyl acetate
— Paint for Dyeing Specified in Structure Repair Manual
1.1.3 Spare parts
— Filler metal plate (Refer to Chapter of “Identification of Materials”)
— Stringer (Refer to Chapter of “Identification of Materials”)
— Stiffener of stringer (Refer to Chapter of “Identification of Materials”)
— Rivets are to be determined according to repair area
1.2 Preparation
Remove parts adjacent to the repair area according to necessity for convenience of
disassembling and riveting.
1.3 Procedures (see detail A in Fig.1)
1.3.1 Preparation
— Determine the limits to be repaired
— Check all parts adjacent to the damaged area for cracks
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— Check rivets in this area for looseness, crack, or deformation and replace them
according to the description provided in 20-03-02-101 in Standard Practices Manual.
— Try as much as possible to remove the damaged parts of skin (1) and stringer (2) by
regular cutting.
— Remove rivets which are affected by the repair performed according to the
description given in task card 20-03-01-102 in Standard Practices Manual.
— Remove burrs and sharp edges.
Note: When carrying out this job, it is necessary to correctly clamp the parts，so as to
eliminate any relative displacements and possible deformations caused by stress
due to removal of structural component.
1.3.2 Cleaning up and checking of locating surface
— Use trichloroethylene to clean the locating surface.
— Check corrosion marks and remove the corrosion according to the description given
in task card 20-03-01-102 in Standard Practices Manual
— Check the elongated rivet hole，to determine the rivet sizes to be used (nominal or
interference sizes)，and determine positions of these holes.
1.3.3 Preparation for repair part and locating surface
— Cut repair part as shown in detail A in Fig.1 and make the following parts of the
same material and thickness as that of the repair area.
— A filler (8)
— A skin stiffener (4)
— A segment of bar section (5) used for repair of stringer
— A segment of stringer stiffener (6).
— Make every part of locating surface according to the description given in
20-02-03-403 in Standard Practices Manual
— On each repaired part, draw the rivet arrangement positions according to the
disassembled rivets and quantity of rivets needed.
— On each repaired part, drill a few technological holes for clamping the fixed parts.
— Locate and clamp stiffener (4) and filler (3) on repaired stringer.
— Disassemble rivets to be replaced from obverse and reverse sides and drill rivet
holes.
Note: The existing holes on stringer (2) and skin (1) can be used as template for drilling
holes.
— Take down repaired parts (3) (4) (5) (6)，remove burrs and from rivet hole.
— Remove chips of drilled holes.
— On each repaired part, perform the surface treatment using Alodine 1200，and then
carry out the paint spraying protective treatment according to the description given
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in 20-02-03-403 in Standard Practices Manual.

1.3.4 Installation of repaired part (see detail B in Fig.1)
1) Recover stringer (2)
— Locate, clamp and rivet stringer (5) and stringer stiffener (6) to stringer (2).
2) Assemble filler (3) and stiffener (4)
a) Apply a coat of PR 1221 B (PR) compound to the surface of stiffener (4) in contact
with skin (1) and recovered stringer as required in 20-05-01-201 in the Standard
Practices Manual.
b) Installation of stiffener
— Installation of stiffener (4) has two kinds of possible schemes
First case (see detail A-B in Fig.1)
Fit stiffener (4) inside skin (1) and under stringer (2). Thickness of metal sheet (4) for
this kind of method shall be limited to 0.6mm，so no sink is required for stringer (2) ,
and fit filler (3) on the outside.
Second case (Fig. 2-3-4)
Fig.2：Repair the punctured skin at the place of profiled angle section.
Fig.3：Repair the punctured skin at the place of T-shaped bar section.
Fig.4：Repair the punctured skin at the place of channel shaped bar section.
Rivet the stiffener (4) on the outside of skin (1). The gap between stringer and stiffener
can be eliminated using filler plate (3).
Install stiffener (4) and filler plate (3) according to any kind of method of above two
methods. Fix and rivet these parts with rivets, keeping the existing pitch (P).
— Use PR 1221 B compound to fill the gap between the filler plate (3) and skin (1)
according to the description given in task card 20-05-01-201 in Standard Practices
Manual.
Note: Loose the fasteners when riveting on the wet compound.
— Apply one more coat of finish paint according to the description given
in20-04-05-701 in Standard Practices Manual.
1.4 Final step
— Install the parts adjacent to the repair area.
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Fig. 1
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Fig. 2
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Fig. 3
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Fig. 4
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REPAIR METHOD OF CRACKED AND PUNCTURED SKIN

AND DAMAGED BULKHEAD
1 Repair of Bent Edge of Bulkhead Flange

This kind of repair general is applicable to frame
1.1.1 Tools
— Standard tool
— Hand shears
— Riveting press
— Pop riveting
— Pneumatic drill
— Riveting press
— Pneumatic riveting gun
— Pop rivet holder
— Drill bit
— Dye penetration test tool
1.1.2 Materials
— Trichloroethylene or ethyl acetate
— Alodine 1200.
— PR 1211 B sealing compound
—Paint for Dyeing Specified in Structure Repair Manual.
1.1.3 Replacement parts
—Metal plate (Refer to Chapter of “Identification of Materials”)
— Rivets are to be determined according to repair area
1.2 Preparation
Remove parts adjacent to the repair area according to necessity for convenience of
disassembling and riveting.
1.3 Procedures (see detail A in Fig.1)
1.3.1 Preparation
— Delimit the area to be repaired
— Check all parts adjacent to the damaged area for cracks
— Check rivets in this area for looseness, crack, or deformation
— Disassemble the rivets on damaged bulkhead flange crimp according to the
description given in 20-03-01-102 in Standard Practices Manual.
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— Cut the damaged bulkhead flange crimp bar section, it is required to try as much as
to cut regularly against the bent side.
1.3.2 Cleaning up and checking of locating surface
— Remove all existing sealing compound according to the description given in
20-05-01-101in Standard Practices Manual.
— Use trichloroethylene to clean the locating surface
— Check corrosion marks and remove the corrosion according to the description given
in 20-04-03-401 in Standard Practices Manual
— Check the condition of skin rivet holes ( such as elongation)，and determine the sizes
of rivet to be used .
1.3.3 Preparation for stiffeners and locating surface (see detail A in Fig.1)
Fig. 1
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— Cut and make stiffener (1) on metal sheet of having the same material and same
thickness as that of repair area.
— Make the stiffener of positioning plane as described in the 20-02-03-101 of the
— Mark rivet arrangement position according to rivets removed and newly added rivets.
— Drill several technological holes on the repair part (1) to tighten the positioning
plane.
— Drill holes for positioning and clamping and drill holes for stiffener (1) in
accordance with existing rivet holes on the skin and new arrangement from skin
outer surface to inner surface .
— Take down stiffener (1) to remove burrs and sharp edges from rivet hole burrs and
sharp edges, and clear away chips from drilled hole.
— Use Alodine1200 to surface treat the stiffener and effected area by repair .
— Apply paint for protection in accordance with as described in the 20-04-05-101 of
the Standard Practices Manual.
1.3.4 Installation of repaired stiffener (see detail B in Fig.1)
— Apply the one coat of PR 1221 B compound to area between stiffener (1), skin (2)
and bulkhead web (4) as described in the 20-05-01-201 of the Standard Practices
Manual.
— Locate, tighten and rivet the repaired part as described in the Standard Practices
Manual.
— Apply the finishing paint in accordance with as described in the 20-04-05-701 of the
1.4 Repair of cracked bulkhead flanged edges (see Fig.2)
Use the repair method specified in Section 1.3.
1.5 Final step
Installation parts which are nearby the repair area.
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REPAIR OF HONEYCOMB STRUCTURE
1 Repair of Honeycomb Structure

Two honeycomb sandwich panels used in aircraft structure：
— Metal honeycomb panel
— Laminated honeycomb panel
2 Repair of Metal Honeycomb Panel
2.1 Repair of cracks of inner and outer skin (see detail A in Fig.1)
For cracks on skin, drill a 2mm-diameter of crack-arrest hole (1)，adhere A-U4G1／5A
panel with the same thickness as that of skin using epoxy resin J-84 (4), rivet using
AVDEL rivet (3) with diameter of 32mm.
2.2 Repair of punctured skin with honeycomb locally damaged
2.2.1 Use epoxy resin J-84 for pouring (see detail B in Fig.1)
2.2.1.1 Procedure
— Delimit the area to be repaired
— Use a punch tool to cut broken skin (1) based on broken out-to-out.
— Tear off and cut the damaged honeycomb sandwich.
— Make one A-V4G1-A5 stiffener (2).
— Pour the epoxy resin J-84 into damaged honeycomb sandwich (3) according to
the description given in task card 20-06-02-303 in Standard Practices
Manual.
— Use epoxy resin J-84 and 3.2mm diameter AVDEL to rivet and adhere the
stiffener (2).
2.2.2 Filling using micro-ballon compound (see detail C in Fig.1)
2.2.2.1 Procedure
— Carry out as per procedure specified in Article 2.2.1.1.
— Use the compound comprised of following components to pour into honeycomb
(3)：
• 75g white epoxy resin121.
• 25 epoxy resin103.
• 5-6g styaty1 951 curing agent.
• 20g micro-ballon powder
2.3 Repair of punctured skin with honeycomb severely damaged (see detail A in Fig.2).
2.3.1 Procedure
— Implement as per procedure specified in Article 2.2.1.1.
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— Use the epoxy resin J-84 bonded honeycomb block (3) 6.25P to fill damaged area.
2.4 Repair of skin glue on metal honeycomb structure (see detail B in Fig.2)
Caution:
This repair method is only applicable to light load structure area which is
not required to be approved by the design department of manufacturer in
advance.
2.4.1 Accessories required
— Screw L22102-50-25 BCL (1)
— Washer L23116-50-DG1 (2)
— Nut L22542-50H (3)
— Epoxy resin AVl03 + curing agent HY 951+ micro-ballon (4)
— Bushing with internal diameter of 6mm and external diameter of 8mm (5)
2.4.2 Operating procedure
1) Drill a hole with diameter of 8.1mm at a place of about 40mm from degummed area
boundary and 100mm away from all direction.
2) Use a marking awl to locally make a diameter of 15 to 20mm between two layers of
skins.
3) Refer to task card 20-04-02-401 in the Standard Practices Manual，remove the
lacquer coat (about 40mm) around the hole with diameter of 8.1mm).
4) Use trichloroethylene to degrease the exposed area.
5) Use Deoxidine 205 or FRAMANOL to pickle the exposed area (refer to task card
20-04-04-402 in Standard Practices Manual).
6) Prepare sufficient quantity of following compound as per the ratio given below:
• Epoxy resin AY 103 100g
• Curing agent HY 951 12g
• Particle filler 25g
7) Use scraper to scrape the above compound into damaged honeycomb area，and
slightly higher than thickness of the panel.
8) Fit bushing (5)，cure for 48 hours，and keep a light pressure.
9) Grind the glue to be flush with skin.
10) Adhere washer (2) using AVl21+HY951 epoxy resin compound by weight ratio of
100／95.
11) Perform paint spraying for decoration (refer to task card 20-04-05-701 in the
Standard Practices Manual).
— Apply prime P 505 F or epoxy resin according to the condition of aircraft.
— Spay the surface paint, and use the dye paint 4080 according to the condition of
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aircraft.
12) Install screw (1), nut (2) and properly fasten them.
3 Repair of Stripped Honeycomb
3.1 Laminated layer
3.1.1 Procedure
— On condition that honeycomb sandwich is not damaged, cut the glass cloth of
stripped layer.
— Use grit 180 emery paper to grind within limits of 30mm around the notch.
— Clean using cloth dipped with acetone.
— Cut the glass cloth as per sizes of ground area..
— Preparation of resin .
• Typical mixing，the valid period of the canned under temperature of 20℃：30min.
• Stratly A228 polyester resin： 100g.
• Cobalt naphthene active agent：0.1cm.
• AEROSIL additive： 5g.
• Stratyl X 8 catalyst：1.5cm.
Note: Pay attention not to pour the catalyst into active agent, and the catalyst can be
added to the compound only before using.
— Use a clean brush or scraper to apply the well mixed resin to glass cloth block
(about 200g of resin per each cubic meter of glass cloth).
— Apply a coat of compound to the grinding area of the damaged segment.
— Use a clean brush or scraper to fast stick the glass cloth to the damaged area.
— Remove the extra compound，pay attention to evacuate the air between glass cloth
and damaged area，ensure the compound is cured，and as soon as it is completely
cured，use grit 180 emery paper to sand extra compound in repaired area.
— Curing time：3 ~ 4h.
3.2 Repair of skin punctured and severely damaged honeycomb sandwich (see detail C in
Fig.2)
3.2.1 Procedure
— Cut skin (1) as per regular contour
— Use grit 180 emery paper to sand within limits of 30mm around the notch.
— Cut the damaged honeycomb body from the repaired place，prepare the honeycomb
filler (2) according to the necessary procedure by the repair.
— Prepare the resin as specified in Paragraph 3.1.1.
— Apply resin to surface of honeycomb filler which in contact with the skin.
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— Put honeycomb filler into a notch to maintain it to be completely cured (2) (curing
time: 3 ~ 4h).
— Cut a piece of glass cloth (4)，immersed with resin and adhere it to honeycomb
sandwich.
— Allow it to cure for 3 ~ 4h.
— Use grit 180 emery paper for sanding.
Note: In case both layers of skins are damaged, the inside shall be adhered with glass
cloth，the outside of the panel with another piece of glass cloth, and then two
sides are to be clamped.
Fig. 1
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Fig. 2
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REPAIR OF LAMINATED STRUCTURE
1 Repair of Laminated Structure (see detail A in Fig.1)

This task card describes the following procedure：
— Repair of damaged resin coat (1)
— Repair of punctured glass cloth (3)
— Repair of broken rib (4)
— Replacement of rib bar section (2)
Note: These repairs should be performed in the dry atmosphere under environment
temperature 15 ~ 40℃ (maximum relative humidity is 70%). In general，the glass
cloth to be used will be specified in Chapter of “Identification of Materials” of the
Structure Repair Manual.
1.1 Repair of damaged resin coat
Prepare the sealing compound mixture as the ration below：
— 100g STRATyL A228 polyester resin
— 3g X 8 curing agent
— 0.06 ~ 0.20g cobalt naphthene
— Add about 5g of AEROSIL glue powder so as to obtain the required fluidity.
Note: This compound shall be mixed before using. Use the emery wheel or grit 80 emery
paper to sand the repaired area.
Use compressed air to blow off all dust.
Make sure the repair area is free from moisture and greasy dirt.
Use a scraper to apply compound.
Allow it to cure for 3~4h.
Use grit 180 emery paper for sanding.
1.2 Repair of punctured glass cloth (see detail B in Fig. l)
— Trim the punctured area into geometry, sand the periphery and chamfer (1).
— Apply release agent to the joint surface of inner and outer blocks (2) in the repaired
segment.
— Use the resin to adhere a piece of glass cloth (3) to the outside (the mixing ration of
resin is the same as that for repair of damaged resin coat (Para. 1.1)). The punctured
glass cloth should be properly covered.
— Stick a central cloth piece (4) of about 20mm more than edge of hole.
— Adhere one more cloth (5) on the previous cloth，of which the dimensions shall be the
same as that of the outside.
— Use the form block (2) to clamp two sides.
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— Allow it to cure for 3h.

— Take out the formed block and use grit 150 emery paper for sanding.
— If necessary，use the compound for leveling (repair of damaged resin is to be treated as
per Para. 1.1).
1.3 Repair of split rib (see detail A in Fig.2)
— Cut the rib from any side of the crack to 40mm.
— Deepen the notch, grind and blow.
— Mix the compound as per the ration specified in repair of damaged resin coat (Para.
1.1).
— Pour the fiber glass mixed compound into the rib cavity.
— Stick a glass cloth piece which is 20mm protruded out of the rib.
— Allow it to cure for 4h.
— Cut the cloth piece to be flush with rib.
— Use grit 150 emery paper to grind the cloth piece.
— If necessary, use the compound for leveling (repair of damaged resin is to be treated as
per Para. 1.1)
1.4 Replacement of rib bar section
1.4.1 Punctured outer glass cloth and damaged rib bar section (see detail B in Fig.2)
— Properly prepare the punctured area and filling glass cloth (1-2) as specified in
Paragraph 1.2.
— Prepare isocyanate foam rib filler (3).
— Preparation stiffener (4) that can be protruded 20mm out of the damaged area.
— Stick the glass cloth, rib filler and stiffener using the compound specified in Para.
1.1.
— Use the formed block (2) to clamp.
— Allow it to cure for 3-4h.
— Grind the protruded part.
— If necessary, use the compound for leveling (repair of damaged resin is to be treated
as per Para. 1.1)
1.4.2 Punctured outer glass cloth and damaged assembly
— It shall be carried out as specified in Para. 1.4.1，but it is required to use a proper
form block to fit the internal stiffener to an assembly.
1.4.3 Repair of rib bar section
Under the condition not in contact with the outer glass cloth layer, cut the damaged rib
bar section, and implement the steps specified in Para. 1.4.1.
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Fig. 1
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Fig. 2
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REPAIR OF WELDING DEFECT
1 Repair of Welding Defect

1.1 General principle
— In any time when using T1G welding for repair, it is required to observe the restraining
conditions below：
• After removal of previous weld seam defects by using methods such as grinding and
chiseling, the complete patch weld of the weld seam is only allowed for one time；
• Allowable local repair of weld seam；
After complete patch weld of the weld seam: once
Under other conditions: twice；
• The repair should be always performed with filler metal T1G welding as specified in
Article 1.3 of 20-02-05-402 in this manual.
• If required, it is compulsory to observe the sequence of welding；
• At any time of operation, it is required to use flame for a proper heating；
• Never weld on clamping part with stress；
• Any weld for repair must be performed by technical workers.
1.2 Typical repair of tubular structure
— The repair may involve：
• Reprocessing of deposition weld bead so as to complete the tightness；
• Replacement of tube element, joint, assembly；
• Filling of long hole；
• The final means is to completely patch weld bead.
1.2.1 Reprocessing of deposition weld bead
The reprocessing of actual allowable deposition weld bead is twice.
1.2.2 Replacement of tube element, fork arm part, assembly (Fig.1detailA-B-C)
If this assembling is not classified as “Submission of Structure Member to
Manufacturer for Approval”, then the replacement of tube elements that affect the fork
arm parts or connecting parts and interchangeability of assembly should be carried out
in the workshop of having tools and assembling fixtures which are required to ensure
the interchangeability and dimensions.
These areas are provided in the Structure Repair Manual of relevant aircraft.
At any time when replacing tube elements，weld seam must be located in the approved
areas 1-2 . Never conduct the repair in areas 3-4 (detail A).
The welding mode as shown in detail B1 shall be preferred to be used for a new welding,
B B
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and use a saw to cut a 3~4mm pipe from the tubing boarder.
The welding substitution method shown detail B2 can be used.
Splicing joint should be avoided. This kind of repair (detail c) is only for reference, and
can only be used for repair of pipes with thickness of less than 0.5mm.
1-2 welding sequence.
a-Position to allow the repaired pipes to be inserted.
b-Final bushing position.
1.2.3 Filling of hole
This work can be conducted twice. Pipe filling can only be performed in the workshop
of having the tools are required for reaming and maintain the interchangeable
dimensions.
1.2.4 Complete recovery of weld seam
— This kind of repair can only be performed in case the other solutions can not be used.
The weld seam can only be in a special workshop and only one repair can be made in
the original place (generally, it is recommended to stagger the first weld seam and the
second weld seam by 4mm).
— Therefore, it is necessary first to carry out the following procedures：
• Use a saw to cut the pipe to be replaced due to overdeformation；
• Straighten the pipe which is sunk within the limits of tolerance；
• It is required to consider beforehand the repair solution to be used so as to avoid
cutting the pipes without thinking；
• Sprayed metal coating is to be removed before welding.
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REPAIR OF COMPOSITE MATERIAL
1 General
— Determine the repair process of glass/resin composite material part .
— The principle of repair mainly consists of blocking holes, cracks or hollowness.
— This standard repair is applicable to all non-critical laminated part or the part which is
classified as secondary parts or class III structure or with surface area of a part of not
more than 20%.
— If it is necessary to repair the critical parts or the parts which are classified as main
structural parts, then the part can only be approved by the Post-Sale Engineering
Department or National Airworthiness Authorities.
2 Materials for Repair
2.1 General
Repair must use fabrics and resins in compliance with part manufacture standard (refer to
Identification of Material of M,R,R parts)，or be carried out using equivalent fabric and
resin.
2.2 Repair of polyester pre-impregnated part
— Fabric 1581 TF 910
— Resin STRATYL A.228
— Fabric1581 VOLAN A
— Resin J-86 or resin HT303
—Fabric 1581 VOLAN A
—Resin J-86 or resin HT303
— Fabric 1581 VOLAN A
—Resin J-86 or resin HT303
2.6 Repair of phenol pre-impregnated part
— Fabric 1581 VOLAN A
— Resin HT303
3 General Repair Principle
— Quantity of fabric layers of comprising the repair must be at least the same as that of
manufactured part.
— Fabric used for repair should be blended with chamfered part on each side of part.
— Chamfer should be proportional to the thickness of the part：
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For example, 0.6mm thick part，length “a” chamfer is about 8mm. This chamfer should be
oversized by 3mm every time when one layer of fabric is increased.
In order to ensure the molding surface of part, the fabric should be laid in layers.
— Maximum outer layer of fabric should be slightly wrapped with chamfer, about 20mm.
— If there is strict requirement for molding surface of parts, the final fabric wrapped on the
chamfer should be ground，so as to obtain a required molding surface.
— During curing of resin，if it is possible, supplementary part should be supported between
two plates or pressure cloth shall be used.
Curing time：
Use resin J-86 to repair 3mm, it shall be 4h under temperature of 20℃ (refer to the task
card 20-06-03-301 of this manual).
With difference of hardening agents used under temperature of 20℃, the curing time will
be 24h or 36h ((refer to the task card 20-06-03-301 in Standard Practices Manual)
4 Health and Safety
The required measures and precautions should be taken，so that it will be in compliance
with resin treatment and hygienic regulations.
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REPAIR OF POLYCARBONATE COVER
1 Repair of Polycarbonate Covers Cracks

1.1 General principle
— All the repair procedures described in this chapter are in compliance with standard
specified by manufacture process division. If a damage due to noncompliance with
standard to be followed are found in operation , operators should：
• As per the Structure Repair Manual of relevant aircraft.
• Or inform manufacturer of information about damages，so as to work out a proper repair
method.
1.2 Procedure
1.2.1 Bonding preparation
— Dilution：
Calculated by weight , add 15 parts of transparent polycarbonate powder (makRol or
KL／UE 8058) into 100 parts of trichloroethane.
Note: Prior to using, polycarbonate powder must be dewatered under 120℃ for 2h，
well mixed bonding compound must be uniform grain free condition.
1.2.1 Precautions
— bonding agent should be mixed in a well ventilated place.
1.2.1.2 Service life
— Bonding agent can not be used any more after it starts to become hardened.
1.2.2 Preparation for cracks
If necessary, re-determine polycarbonate cracked position as shown in detail A in Fig. l.
1.2.3 Surface preparation
1.2.3.1 Paint sprayed surface
— Sand lacquer coat using a grit 180 to 120 emery cloth.
— Degrease the surface using cloth dipped with ligroin.
1.2.3.2 Non- paint sprayed surface
— Degrease the surface using cloth dipped with ligroin.
1.2.4 Preparation of the fabric to be used by repair
1.2.4.1 Selection of fabric
— CENIN 1581 VOLAN A fabric
1.2.4.2 Preparation of patch cloth according to types of repair.
1) Single faced repair (see detail B-C in Fig.1)
For 1 ~ 2mm thick Polycarbonate 80 ~ 20 (1)，it is required to use three layers of
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GENIN 1581 VOLAN A(3) fabrics as shown detail B to cover cracks (2). For 2～
4mm thick Polycarbonate 80 ～ 20 (4) ， it is required to use five layers of
GENIN1581 VOLAN A Fabric (3) as shown in detail C to cover cracks(2).
2) Double sided repair (see detail A-B in Fig.2)
For 1~2mm thick Polycarbonate 80 ~ 20(1)，it is required to use two layers of
GENIN 1581 VOLAN A(3) fabrics as shown detail A to cover cracks on both
sides.
For 2 ~ 4mm thick Polycarbonate 80 ~ 20 (4)，it is required to use five layers of
GENIN1581 VOLAN A Fabric (3) as shown in detail B to cover cracks (2) on both
sides.
1.2.5 Laying of repair cloth
1.2.5.1 Use the adhesives to impregnate fabrics
— Use a scraper to manually soak the fabric sticking patch with adhesives.
— With adhesives saturated, fabric becomes semi-transparent status：This feature
makes possible check the impregnation extent of whole sticking patch.
— After impregnated，use a scraper to remove the extra adhesives so as to let the
sticking patch be almost clean.
1.2.5.2 Lay sticking patch saturated with adhesives
1) Fabric sticking patch must be laid onto repair surface after it has been
impregnated by adhesives for 5 seconds.
2) Fabric sticking patches should be laid according to their cut sequence.
3) Use a scraper to strike every piece of cloth that is laid on the repaired surface.
Note: If adhesive is dried too fast, it can be activated using a clean cloth dipped
with dichloroethane.
1.2.5.3 Drying time
— Minimum drying time under room temperature is 5 hours.
1.3 Operation precautions
— The repair must be carried out in well ventilated place.
— Adhesives must be kept away from open fire .
— Adhesives absolutely should not be in contact with skin
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Fig. 1
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Fig. 2
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REPAIR OF NON-SLIPPING COVER
1 General
Safety traveling non-slipping cover including：
— Strutting piece made of fiber cloth or aluminum
— Phenolic resin coat
— Electronic silicon carbide particles covered with phenolic resin coating.
Fiber strutting piece can be pre-bonded.
Under this condition, use a blue nylon protective cover for covering.
Aluminum strutting piece shall always be pre-bonded and be protected by a colored kraft
coated with silicon resin.
1.1 Two types of anti-slip covers
The anti-slip type shall be decided by intrinsic quality of strutting piece of receiving the
electronic silicon carbide particles.
Fiber strutting piece: Normal type
Aluminum strutting piece: Formable type
1.1.1 Normal type
No matter that is pre-bonded or not，the normal type will be used for plane or slightly
curled single camber. The fact proves that if curled，fiber strutting piece is very hard
and brittle.
The non pre-bonded anti-slip type is marked with letters “Medium tyPe A” (middle
sized A) on side of fiber.
1.1.2 Formable type
As it is the aluminum strutting piece，so this kind of anti-slip type can be easily formed
at cambered place，even this camber contour is along several single faces (e.g. in bent).
1.2 Thorough replacement of locally damaged skin
No matter what kind of anti-slip type is used, it should be carried out according to the
following working procedure.
— Cut the damaged portion，and at least one of the four connections should be in the
existing connection on the edge or center part.
— Use a tool blade to cut along the straight flange，pay attention not to damage skin panel
under the cover, and cut off the part to be replaced.
— Use a cloth dipped with methylbenzene to clean skin panel to remove sticker.
— Cut a safe traveling anti-slip plate according to the size of damage portion：Locate the
plate, take corresponding steps, cut and punch as required
Note: The anti-slip type provided under pre-bonded condition in this stage is not required
20-03-08-401
Jul. 15/2010 Page 1
to be coated with adhesives，strutting piece is only required to be adhered in this

kind of condition.
— Apply EC 870 or EC 711 adhesive to the cover and skin panel, until the adhesive film
is dried to the extent that is not stuck to fingers, and when lightly touched, its adhesive
performance shall be maintained (the dry time is about 15min).
— Install the anti-slip cover and compress it so that each point can be properly adhered.
Note: If an anti-slip cover is used on plane，carefully press out the air that is possibly
existed between strutting piece and anti-slip cover from one end. If anti-slip part is
used on camber，press outward from the center to prevent any air bubbles from
occurring.
As for formable anti-slip piece，it is required to use a rubber hammer to lightly hit its
surface outward from the center.
— During polymerization, it is required to use a special device to fix anti-slip cover in
position so that the maximum surface can be adhered.
— Use methylbenzene to clean extra adhesive immediately.
1.3 Repair of air bubbled anti-slip cover
Use an awl to make holes on air bubble from several points.
Use a dermo-injector with needle head pour in EC870 adhesive through bore-hole, and
after 5 to 15 minutes, compress air bubble, immediately clean extra adhesive.
Note: The following adhesives can be used to substitute for EC870：
— EC1236 adhesive.
— Safety walk adhesive agent.
— ZC711 adhesive.
For coating, see Chapter 20-06 in Standard Practices Manual.
1.4 Maintenance of non-slipping cover
When anti-slip part is dirty or blocked by dirt，it can be cleaned using a brush, or washed
in soap water，then it shall be rinsed with care in fresh water and wiped dry using a
sponge.
During all the these maintenances, be careful to avoid using sundex，because it may
damage adhesives, causing the anti-slip pad to be partially or integrally disengaged.
20-03-08-401
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Z9 Helicopter Maintenance Manual

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Z9EH HELICOPTER

ORIGINAL ISSUE: Jul. 15/2010

AVIC HARBIN AIRCRAFT INDUSTRY GROUP CO., LTD.

GENERAL LIST OF EFFECTIVE PAGES

Chap-Sec-Sub No. Page No. Date

GENERAL LIST OF EFFECTIVE PAGES

Chap-Sec-Sub No. Page No. Date

Chap-Sec-Sub No. DESCRIPTION

RECORD OF TEMPORARY REVISIONS

Record of Temporary Revisions

LIST OF SERVICE BULLETINS

List of Service Bulletins

Chap-Sec-Sub No. Page No. Date

Chap-Sec-Sub No. Page No. Date

20-01-01-304 2 Jul. 15/2010

CLEANING, PROTECTION TREATMENT AND SPRAYING COATING

Chap-Sec-Sub No. Description

20-01-01-101 Various Kinds of Materials Used in Helicopter

20-01-01-301 Lubricating Grease

20-01-01-302 Lubricating Oil

20-01-01-303 Protection Materials

20-01-01-304 Special Material

20-01-01-305 Hydraulic Oil

20-01-01-306 Jet Fuel

20-01-01-310 Polysulfide Sealing Compound

20-01-01-311 Fluorocarbons sealing compound

20-01-02-101 Deionized Water

20-01-02-401 Use of Water

20-01-02-601 Analysis of Water

20-01-03-101 Selection of Aluminum Alloy

VARIOUS KINDS OF MATERIALS USED IN HELICOPTER

1 Lubricating Grease， Lubricating Oil， Special Material， Protection Material，

VV— American Federal Specifications.

2.1.2 Application mode as per symbols:

Symbol Application Mode Number Signs Application Mode Number

Specifications Technical Data

-40 240 KALOR KALOR H

-40 210 NYCO GREASE H

-40 > SHELL AEROSHELL H

4206B G355 MIL.C. DEF -40 Min. BURMAH CASTROL H

Specifications Technical Data

4206B -40 Min. BURMAH CASTROL H

-40 185 KALOR GRAISSE H

-40 Min. SHELL AEROSHELL H

4207A G61 DTD -54 > 260 BURMAH CASTROL H

Specifications Technical Data

-40 308 NYCO GRAISSE H

-54 > SHELL AEROSHELL H

4210B G54 MIL.G. DEF -73 188 BURMAH CASTROL H

-73 > 170 ESSO 5114 EP H France

-73 181 KALOR KALOR H

-73 297 NYCO GRAISSE H

Specifications Technical Data

-73 184 RAFF GRAISSE H

-73 260 SHELL AEROSHELL H

4214B G363 MIL.G DEF 177 BURMAH CASTROL H

-10 190 NYCO GRAISSE H

Min. SHELL AVIATION H

Specifications Technical Data

4215B G382 MIL.G. DEF -40 > 260 BURMAH CASTROL H

-40 150 EIF ELF H

-40 192 ESSO AVIATION H

-40 194 KALOR GRAISSE H